METHOD AND SYSTEM FOR IMPROVING A PHYSICAL PRODUCTION PROCESS

Abstract

The invention relates to a method and system wherein an analysis system (6) measures derivative process parameters (7) from the derivative physical production process, wherein the precursor charge (3) is produced at a precursor production facility (8) at least 50 km distant from the physical production facility (2) through a precursor production process based on applied precursor production settings (9), wherein the precursor charge (3) is transported to the physical production facility (2), wherein the analysis system (6) measures precursor process parameters (11) from the precursor production process and precursor product parameters (12) from the precursor charge (3), wherein the analysis system (6) enters the applied derivative process settings (4), the measured derivative process parameters (7), the applied precursor production settings (9), the measured precursor process parameters (11), the measured precursor product parameters (12) as input to a process model (13), which process model (13) describes a computational relationship between derivative process settings, derivative process parameters, precursor production settings, precursor process parameters and precursor product parameters, to obtain updated derivative process settings (15).

Claims

1.-16. (canceled)

17. Method for improving a physical production process, wherein a derivative physical product is produced at a physical production facility through a derivative physical production process from a precursor charge of precursor material based on applied derivative process settings, wherein an analysis system measures derivative process parameters from the derivative physical production process, wherein the precursor charge is produced at a precursor production facility through a precursor production process based on applied precursor production settings, wherein the analysis system measures precursor process parameters from the precursor production process and precursor product parameters from the precursor charge, wherein the analysis system enters the applied derivative process settings, the measured derivative process parameters, the applied precursor production settings, the measured precursor process parameters, the measured precursor product parameters as input to a process model, which process model describes a computational relationship between derivative process settings, derivative process parameters, precursor production settings, precursor process parameters and precursor product parameters, to obtain updated derivative process settings for matching user-defined derivative product specifications describing derivative product parameters, wherein the updated derivative process settings are applied to the derivative physical production process, characterized in that the precursor production facility is at least 50 kilometers distant from the physical production facility and that the precursor charge is transported to the physical production facility.

18. Method according to claim 17, wherein, the updated derivative process settings are applied to the derivative physical production process for the derivative physical product from the precursor charge.

19. Method according to claim 17, wherein, the analysis system measures derivative product parameters from the derivative physical product, that the analysis system matches the measured derivative product parameters to the user-defined derivative product specifications and that the analysis system also enters the measured derivative product parameters as input to the process model and that the process model extends the computational relationship to the measured derivative product parameters.

20. Method according to claim 19, wherein, derivative product parameters from the derivative physical product are measured using optical inspection techniques.

21. Method according to claim 17, wherein, a series of successive charges of derivative physical products are produced through the derivative physical production process from a series of respective precursor charges of precursor material, preferably, that the analysis system (6) uses data input to the process model from production of the series of successive charges to update the process model, in particular, that the updated derivative process settings are applied to the derivative physical production process for a subsequent derivative physical product from a subsequent precursor charge.

22. Method according to claim 17, wherein, based on the input to the process model by the analysis system, the analysis system provides updated precursor production settings and that the updated precursor production settings are applied to the precursor production process.

23. Method according to claim 17, wherein, based on the input to the process model by the analysis system, the analysis system determines a precursor suitability information regarding that precursor charge for matching the user-defined derivative product specifications.

24. Method according to claim 17, wherein, based on the input to the process model by the analysis system, the analysis system determines a defect risk of the derivative physical product from the precursor charge, that the analysis system outputs a defect signal if the determined defect risk exceeds a predetermined defect risk threshold.

25. Method according to claim 24, wherein, the defect risk of the derivative physical product from the precursor charge is determined prior to completion, in particular prior to the start, of the derivative physical production process of the derivative physical product from that precursor charge, that the defect signal is output prior to completion, in particular prior to the start, of the derivative physical production process of the derivative physical product from that precursor charge.

26. Method according to claim 17, wherein, the analysis system measures a course of derivative process parameters and/or a course of the precursor process parameters and/or a course of the precursor product parameters substantially continuously during a respective measurement period of the derivative process parameters and/or the precursor process parameters and/or the precursor product parameters, that the analysis system measures a course of derivative product parameters substantially continuously during a respective measurement period of the derivative product parameters.

27. Method according to claim 17, wherein, the derivative physical production process is an injection molding process, that the derivative physical product is an injection molded product and that the precursor charge is a granular polymer charge for injection molding.

28. Method according to claim 17, wherein the precursor charge is produced through a precursor production process from a starting material.

29. Method according to claim 28, wherein, the analysis system measures starting material parameters from the starting material, that the computational relationship of the process model extends to the starting material parameters and that the analysis system also enters the measured starting material parameters to the process model as input, that the computational relationship of the process model extends to the additive parameters and that the analysis system also enters the measured additive parameters to the process model as input.

30. Method according to claim 17, wherein, the precursor production process may comprise a compounding process for producing a granular polymer charge for injection molding from the starting material, and at least one additive, that the precursor production process is performed by a heated twin-screw extruder.

31. Method according to claim 17, wherein the analysis system comprises a display apparatus visually outputting, substantially in real-time, the measured derivative process parameters and/or the updated derivative process settings and/or the measured precursor process parameters and/or the measured precursor product parameters, that the display apparatus visually outputs the measured derivative product parameters.

32. System for improving a physical production process comprising a physical production facility for producing a derivative physical product through a derivative physical production process from a precursor charge of precursor material based on applied derivative process settings and comprising an analysis system for measuring derivative process parameters from the derivative physical production process, the system further comprising a precursor production facility for producing the precursor charge, the analysis system is further configured to measure precursor process parameters from the precursor production process and to measure precursor product parameters from the precursor charge, wherein the analysis system is further configured to enter the applied derivative process settings, the measured derivative process parameters, the measured precursor process parameters and the measured precursor product parameters as input to a process model, which process model is saved in the analysis system and which process model is configured to describe a computational relationship between derivative process settings, derivative process parameters, precursor production settings, precursor process parameters and precursor product parameters, to obtain updated derivative process settings for matching user-defined derivative product specifications, wherein the precursor production facility is at least 50 kilometers distant from the physical production facility.

Description

[0052] Further advantageous and preferred features are discussed in the following description with respect to the FIGURES. In the following it is shown in

[0053] FIG. 1 a schematic view of an embodiment of the system according to the invention for carrying out the method according to the invention.

[0054] The system according to an embodiment of the invention shown in FIG. 1 concerns a physical production process and in particular a derivative physical production process for producing a derivative physical product 1 as part of a series of derivative physical products 1. In the present example, the derivative physical production process is an injection molding process, derivative physical product 1 is an injection molded product. The described system comprises a physical production facility 2 at which the derivative physical production process is executed to produce the derivative physical product 1.

[0055] At the physical production facility 2, the derivative physical product 1 is produced from a precursor charge 3 of precursor material, which in the present example is a granular polymer charge for injection molding and in particular a polycarbonate charge of polycarbonate material. For the production from that precursor charge 3, derivative process settings 4 are applied to the production and in particular to machines 5 of the physical production facility 2 for the derivative physical production process. In the present case the machines 5 may are embodied as injection molding machines as shown in FIG. 1.

[0056] The described system further comprises an analysis system 6, which in the present example is a distributed computer system, which measures derivative process parameters 7 from the derivative physical production process, e.g. from appropriate measurement instruments, in particular a plurality of sensors, of the machines 5 in the physical production facility 2. The analysis system 6 also measures derivative product parameters 16 from the derivative physical product 1 itself. The derivative product parameters 16, e.g. the dimensions of the derivative product, surface contour deviations, surface roughness or surface finish, may be measured by means of optical inspection techniques, in particular using visual light. For measuring e.g. the temperature distribution in the derivative product IR light techniques may be applied.

[0057] The described system also comprises a precursor production facility 8 which is arranged at a distance of about 100 kilometers from the physical production facility 2 at which the precursor charge 3 and in particular a series of precursor charges 3 for the production of the series of derivative physical products 1 is produced in a precursor production process from starting material 18, which is presently a polymer precursor, and further additives 19. Here, the precursor production process comprises both a polycondensation process as well as a compounding process. For the precursor production process, precursor production settings 9 are applied to precursor machines 10 in the precursor production facility 8 for producing the precursor charge 3. Each produced precursor charge 3 is transported to the physical production facility 2.

[0058] The analysis system 6 also measures precursor process parameters 11 from the precursor production process and in particular from instruments of the precursor machines 10. In addition, the analysis system 6 measures precursor product parameters 12 from the precursor charge 3, which in the present example takes place in the precursor production facility 8, starting material parameters 20 from the starting material 18 and additive parameters 21 from the additives 19.

[0059] A process model 13, which in the present example is a numerical simulation software module, is saved in the analysis system 6 along with user-defined derivative product specifications 14, which describe required parameter brackets for a set of derivative product parameters. The analysis system 6 also matches the measured derivative product parameters 16 to the user-defined derivative product specifications 14 to determine for each derivative physical product 1 whether it meets the user-defined derivative product specifications 14.

[0060] The applied derivative process settings 4, the measured derivative process parameters 7, the applied precursor production settings 9, the measured precursor process parameters 11, the measured derivative product parameters 16, the measured starting material parameters 20, the measured additive parameters 21 and the measured precursor product parameters 12 are all entered as input to the process model 13. The process model 13 is configured to process the input and establish complex computational relationships between the data that is input. Thus, based on the input it becomes possible to determine a probability for meeting the user-defined derivative product specifications 14 or for a certain defect occurring.

[0061] The measurement by the analysis system 6 proceeds continually. Thus, based on a change in the measured derivative process parameters 7, such as an increase of the temperature in a process chamber of the physical production facility 2, the applied derivative process settings 4 are adjusted by applying updated derivative process settings 15 obtained by the input entered into the process model 13. For example, the above increase in temperature may result in the adjustment of a valve to prevent a defect occurrence from the increased temperature in the ongoing derivative production process. Also, the ongoing entering of input to the process model 13 in particular with respect to the measured derivative product parameters 16 permits a successive updating of the process model 13.

[0062] It may also be that based on the measured precursor product parameters 12 and precursor suitability information determined on its basis by the analysis system 6 using the process model 13, a particular precursor charge 3 is identified as unsuitable for meeting the user-defined derivative product specifications 14 and therefore removed for this particular application to be used for a process for which the measured precursor product parameters 12 appear more suitable. The analysis system 6 may also generate a defect risk quantifying the risk of missing the user-defined derivative product specifications 14 with that precursor charge 3.

[0063] On the other hand, it may also be that any expected negative effects based on the measured precursor product parameters 12 may be compensated for by an appropriate adjustment in the updated derivative process settings 15, which may therefore be used for that particular precursor charge 3. In addition, the process model 13 may provide the analysis system 6 with updated precursor production settings 17 to be applied to the precursor production process for preventing the future occurrence of unsuitable precursor charges 3. Also, the analysis system 6 comprises a display apparatus 22 for outputting in real-time the measured derivative process parameters 7.