Virtual Workpiece Tracking Using State Machines for Process Data Association
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Solution Overview
Problem
Existing data collection systems for manufacturing apparatuses face challenges in associating process data with workpieces when the workpiece ID is not available or difficult to read, and altering control software is costly and inefficient, requiring modifications for each apparatus.
Innovation Solution
A data collection system that uses an event data collector, state machine generator, and state machine driver to create virtual workpieces with IDs, allowing for the association of process data with actual workpieces through sensors, enabling efficient tracking and analysis of processing processes without requiring extensive software changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the workpiece ID is read and associated with process data, then data tracking and analysis capability is improved, but the system cannot be applied when the ID does not accompany the workpiece or when it is difficult to read the ID
Solution Approach 1:
The patent creates a virtual copy of the workpiece (virtual workpiece) that mirrors the actual workpiece's processing journey. This virtual workpiece is generated from process data and sensors without requiring physical ID tags on the actual workpiece, enabling tracking through data replication rather than physical identification
Solution Approach 2:
The patent introduces a workpiece information management device as an intermediary that collects process data and sensors data, generates virtual workpieces, and associates them with actual workpieces. This intermediary layer enables tracking capability without requiring direct ID reading from the workpiece itself
2Loss of information
If the control software is altered to perform data collection with workpiece association, then data tracking capability is improved, but the cost of software alteration becomes large and requires modification for each manufacturing apparatus
Solution Approach 1:
The workpiece information management device is designed as a universal system that can be applied to various manufacturing apparatuses without requiring apparatus-specific software modifications. It collects process data through standardized interfaces and generates virtual workpieces that work across different equipment types
Solution Approach 2:
By positioning the workpiece information management device as an intermediary between the manufacturing apparatus and the data analysis system, the patent avoids the need to modify the control software of existing manufacturing equipment. The intermediary collects necessary data through sensors and process data interfaces without altering the original system
Data Source
AI summary
According to one embodiment, a data collection system includes an event data collector, a state machine generator, a state machine list, and a state machine driver. The event data collector collects sense signals respectively as a plurality of event data. The state machine generator generates a state machine as a model corresponding to the workpiece. One of the sense signals is acquired when the workpiece is fed into the processing system. The state machine generator generates the state machine and generates an ID for the state machine when the event data collector collects one of the plurality of event data corresponding to the one of the sense signals. The state machine driver drives the state machine retained in the state machine list by sending, to the state machine retained in the state machine list, an event corresponding to another one of the sense signals.