Upstream Process Control Method for Product Quality and Rate

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Solution Overview

Problem

Existing control methods struggle to harmonize the operation of upstream and downstream processes in product manufacturing, leading to interruptions that affect production rate and product quality, particularly when interruptions impair the quality of conditioned products or result in excessive accumulation.

Innovation Solution

A control method that monitors performance indicators of both processes to adjust the upstream process's duty cycle, ensuring it slightly overfeeds the downstream process while minimizing interruptions, using empirical formulas to optimize the rate of product delivery and maintain product quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the upstream process operates at a high rate to meet downstream demand, then productivity is improved, but interruptions are required to prevent unwanted accumulation of conditioned product

Engineering Contradiction:

Improveproduction rateVSAvoidproduct quality consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control method continuously monitors the duty cycle of the upstream process and the performance indicating variable of the downstream process, using this feedback information to dynamically adjust the upstream process rate and prevent both accumulation and interruptions

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts the upstream process operating rate based on real-time conditions, transitioning from static fixed-rate operation to adaptive variable-rate operation that responds to downstream demand and upstream process state

Inventive Principle:

Principle #15Dynamics

2Productivity

If the upstream process is stopped and restarted to prevent accumulation, then productivity is maintained, but product quality deteriorates due to cooling time and heating time effects

Engineering Contradiction:

Improveproduction continuityVSAvoidproduct quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The control method predicts when interruptions would be necessary based on monitored parameters, and takes preliminary action to adjust the duty cycle to prevent accumulation, thereby avoiding the quality-deteriorating stop-start cycle entirely

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The method converts the potential harm of unwanted accumulation into a beneficial control signal that adjusts the upstream duty cycle, transforming what would be a reason for interruption into an opportunity for smooth rate adjustment

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If the upstream process operates slightly over the downstream demand rate, then productivity is maximized, but unwanted accumulation of conditioned product occurs

Engineering Contradiction:

Improveproduction rateVSAvoidconditioned product accumulation

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The system changes the operating parameters of the upstream process dynamically, adjusting the duty cycle based on the difference between downstream demand and upstream delivery rate, allowing optimal rate matching without fixed overfeeding

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3245488B1Method of controlling a rate at which an upstream process feeds a conditioned product to a downstream process

Publication Date: 2019.06.05 HEAT & CONTROL INC

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AI summary

A method of controlling an upstream and a downstream process wherein the upstream process conditions a stream of product delivered to the downstream process is provided. The control method uses an empirically determined formula to determine a metric for adjusting the activity of the upstream process to thereby adjust the rate with which the upstream process conditions and feeds a stream of conditioned product to the downstream process. The empirically determined formula determines the metric using two input variables: a duty cycle setting of the upstream process and an output rate of the downstream process expressed as a decimal amount of the output rate set-point.