Downstream TPU Production Control for Consistent Article Quality
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Solution Overview
Problem
The production of articles from thermoplastic polyurethane (TPU) and expanded thermoplastic polyurethane (ETPU) faces challenges in achieving consistent quality due to variations in manufacturing parameters and precursor material properties across the value chain, leading to inconsistent product quality and increased costs.
Innovation Solution
A method using a downstream computing unit to determine control settings based on precursor data, desired performance parameters, and historical data to control the production process, ensuring consistent quality by accounting for variations in TPU and ETPU material properties and process parameters across equipment zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional time series approaches are used for machine learning in continuous manufacturing processes, then vast amounts of production data can be collected, but it becomes difficult to integrate data according to the needs of horizontal integration across the value chain
Solution Approach 1:
The patent segments the continuous production process into discrete batch records, with each batch representing a manageable unit of data. This segmentation allows data to be organized by production batches rather than as continuous time series, making it easier to integrate across the value chain while maintaining the ability to track vast amounts of production data through structured batch-level information
Solution Approach 2:
The patent introduces batch records as an intermediary data structure that bridges upstream and downstream processes. These batch records serve as standardized containers that can be exchanged between different stages of the value chain, facilitating horizontal integration while managing the complexity of vast production data through a unified intermediate format
2Ease of manufacture
If upstream and downstream industrial plants operate independently with separate control systems, then each plant can optimize its own production, but the properties of articles produced at the downstream plant vary due to variations in precursor material from the upstream plant
Solution Approach 1:
The patent implements feedback mechanisms where batch records from upstream plants are transmitted to downstream plants, enabling the downstream control system to adjust its processing parameters based on the actual properties of incoming precursor materials. This feedback loop maintains manufacturing precision despite operational independence, as each plant can adapt its control settings based on real-time information about material variations
Solution Approach 2:
The patent creates a universal batch record format that serves multiple functions across the value chain: it tracks material properties at the upstream plant, serves as a communication interface between plants, and guides processing parameters at the downstream plant. This multi-functional data structure enables both operational independence and consistent article quality through a standardized information exchange mechanism
Data Source
AI summary
A method can be used for controlling a downstream production process for manufacturing an article at a downstream industrial plant, by processing at least one thermoplastic polyurethane (“TPU”) and/or expanded thermoplastic polyurethane (“ETPU”) material using the downstream production process. The method involves providing, at a downstream computing unit, a set of downstream control settings for controlling the production of the article. The downstream control settings are determined based on a downstream object identifier; at least one desired downstream performance parameter related to the article; and downstream historical data. The set of downstream control settings is usable for manufacturing the article at the downstream industrial plant. A corresponding system for downstream production, use, and software product are provided.