Classifications

• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06F—ELECTRIC DIGITAL DATA PROCESSING
  • G06F30/00—Computer-aided design [CAD]
  • G06F30/20—Design optimisation, verification or simulation

Definitions

• TITLE COMPUTER BASED SYSTEM FOR IMAGING AND
• the present invention relates to engineering problem solving and design tools and more particularly to computer based systems for aiding engineers, scientists and the like to have a greater understanding of the products, processes, or machines they wish to improve and the technical problems related thereto that they wish to solve.
• CAD computer aided design
• CAE computer aided engineering
• the CAD system also generates virtual 3-D images of the product or
• this system includes a large data base of physical
• this system includes a technology evolution and prediction
• the EAS according to the
• object system which functional model of an object, device, machine, or other engineering system (hereafter termed "object system") includes the major components,
• the EAS prompts the user to input data that enables the EAS to perform a parameter
• the EAS analyzes the functional model elements, conducts an interaction parameter analysis, conducts an object system component function
• the EAS includes an Initial Data routine that prompts the user to input analysis or session qualitative and quantitative objectives in re-designing an engineering system or object.
• the EAS After entering initial data, the EAS next prompts user to create an image of a functional
• a Functional Model routine displays an image of a functional model of the current session object and allows the user to edit it or complete the statement to generate the functional and
• the Functional Model routine includes three alternate modes to enable the user
• the EAS also prompts user to apply to the functional model or an interaction matrix
• the EAS also prompts user to input
• the EAS then analyzes the model components and interactions and formulates
• the EAS provides a Trimming routine during which the object system functional model is analyzed, evaluated, and the functions and problems of each object system
• the system re-analyzes the object system and recommends the components that
• the EAS conducts each analysis on either of two levels of depth as selected by the
• the EAS indicates to the user new and powerful information about the object, each component of the object, and each interaction between such components and each supersystem and any products produced or conveyed by the object.
• the EAS hereof in a Problem Management routine indicates to the user which components to try to modify or trim and eliminate their functions or transfer their functions to other components of the object system. The results also aid the user in identifying the core technical problems to be solved to produce the greatest value and the technical problems that disappear and need no solution if the trimming effort is successful.
• the EAS also includes the ability to generate a report at the end of each session describing all analysis steps, the original and trimmed object system, lists of detected problems, received concepts, object structure changes, feature transfer recommendations and results of the session.
• the EAS also includes a Process System Analysis module (hereafter "PSA") that assists the user to analyze a process system intended to be modified or designed to improve a manufacturing, treatment, or other physical effectiveness, process (Process System) energy consumption, cost. time, number of steps, material consumption, pollution, space, or waste.
• PSA Process System Analysis module
• the Process System Components and Operations, each Component being made, modified or added by a sequence of one or more Operations, each Operation being performed by a sequence of one or more Functions or steps.
• the PSA module enables the user to analyze manufacturing, engineering, medical or technical processes from different perspectives and at several different levels of abstraction. The user first examines Components that are produced during a process, then the Operation that produces each individual component, and finally the various Functions that make up each discrete operation.
• the PSA constructs graphical models of Components that are produced in the process, as well as a graphical Function model.
• Process (Link) Analysis is performed, and a new,
• the Process System Analysis module includes five major routines:
• Component Model stage that displays an image of the sequence of Components produced or added during the process and that allows the user to edit or complete the
• Component Model display The user begins this stage by drawing a model structure of the operations and their sequence.
• Each process has a hierarchy: a process can be reduced to
• components which are produced during the process; the components can be further reduced to operations that produce them.
• the operations are further made up of functions, each consisting of three parts: an element or tool, an action, and an element or tool that receives the action.
• the user can start the analysis on the highest level of the hierarchy and analyze the lower levels of the hierarchy subsequently, if necessary.
• Process (Functional) Analysis stage prompts the user to enter data for the functional and interaction relationships of the Functions and Operations that produce each Component of
• This routine further enables the user to (i) identify tools and parts of components used or addressed during the respective operation, (ii) rank each useful Function according to the
• PSA supports two levels of link analysis.
• the primary level, called actions analysis, requires very little information for the description of the action.
• Each function is
• Harmful actions are also scored from least harmful to most harmful.
• the second level of analysis is advanced link analysis, which allows the user to define functional performance in terms of associated parameters.
• Parameters analysis includes parameters of the actions. For every useful action, each parameter actual and required values,
• the PSA determines the degree of discrepancy between actual and required values of useful parameters, or between actual and
• the effectiveness of the process can be defined by the user.
• Trimming is a PSA routine for eliminating or simplifying an operation in a process
• the Trimming stage is based on the benefit
• a process can be simplified by eliminating certain component operations of the process, while redistributing the operations' useful functions to other operations or to non-processed components. Redistributing functions means fewer and simpler operations. Eliminating
• Trimming routine calculates the values of and ranks the Operations or Functions to
• This routine develops the Process Function Rank for each Operation, its Process Problem Rank and Cost.
• the Trimming routine then presents a set
• Trimming stage provides the following benefits:
• Trimming conditions are methods of redistributing the useful functions of an
• PSA will discourage the removal of a useful function, without transferring its action
• PSA provides trimming conditions that correctly transform the process structure. All useful actions
• Problem Manager routine manages the problem statement and displays, and stores parts of the entire session and generates a list of problems to be solved in achieving the redesign objectives. In addition, Problem Manager ranks each problem to display the relative importance in solving such problems. PSA, accordingly, collects this information, correlates it with the
• the PSA makes significant recommendations to the user about which
• Problem Manager can collect organize, and print out a report
• Figure 1 is a block diagram of one exemplary embodiment of an engineering analysis
• Figure 2 is a diagrammatic representation of a personal computer which can form a part of the EAS and enable user interaction described below.
• Figure 3 is a flow diagram of the major sub-sessions or stages of EAS analysis.
• Figure 4 is a block diagram of the Action Task significance routine.
• Figure 5 is a block diagram of the component Problem Rank routine.
• Figure 6 is a block diagram of the routine for calculating a task significance for a new
• Figure 7 is a block diagram of the routine for generating the EAS component trimming
• Figure 8 is a visual display device screen illustrating a display for inputting data
• Figure 9 is a visual display device screen illustrating a display for inputting data
• Figure 10 is a visual display device screen illustrating a display for inputting data
• Figure 1 1 is a visual display device screen illustrating a display for inputting data
• Figure 12 is a visual display device screen illustrating a display for inputting the data
• Figure 13 is a visual display device screen illustrating a display for inputting data
• Figure 14 is a visual display device screen illustrating a display for inputting data
• Figure 15 is a visual display device screen illustrating a display for inputting data and displaying parameter qualitative value link analysis.
• Figure 16 is a visual display device screen illustrating a display for inputting data and displaying time dependency link analysis.
• Figure 17 is a visual display device screen illustrating a display for inputting data
• Figure 18 is a visual display device screen illustrating a display for inputting data
• Figure 19 is a visual display device screen illustrating a display for inputting data and displaying data similar to Figure 13 but for a different, harmful action analysis.
• Figure 20 is a visual display device screen illustrating a display for inputting data and displaying the user choice of component trimming.
• Figure 21 is a visual display device screen illustrating a display for inputting data and displaying trimming parameter evaluation functional rank.
• Figure 22 is a visual display device screen illustrating a display for inputting data
• Figure 23 is a visual display device screen illustrating a display for inputting data
• Figure 24 is a visual display device screen illustrating a display for inputting data and displaying trimming integrated component evaluation.
• Figure 25 is a visual display device screen illustrating a display for inputting data and displaying trimming condition.
• Figure 26 is similar to Figure 12 and displays the trimmed functional model of the object system.
• Figure 27 is a visual display device screen illustrating a display for inputting data and displaying the expert mode analysis level.
• Figure 28 is a visual display device screen illustrating a display for inputting data and displaying the expert mode product element definition.
• Figure 29 is a visual display device screen illustrating a display for inputting data and displaying the expert mode supersystem element list.
• Figure 30 is a visual display device screen illustrating a display for inputting data and displaying the expert mode object component definition.
• Figure 31 is a visual display device screen illustrating a display for inputting data and displaying expert mode level of analysis hierarchy.
• Figure 32 is a visual display device screen illustrating a display for inputting data and displaying expert mode matrix of interaction.
• Figure 33 is a visual display device screen illustrating a display for inputting data
• Figure 34 is a visual display screen illustrating a display screen for inputting data
• Figure 35 is a visual display screen illustrating a display screen for inputting data and displaying the first screen of the feature transfer routine.
• Figure 36 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer object data.
• Figure 37 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer Integrated Result.
• Figure 38 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer Recommendation.
• Figure 39 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer advanced alternative approach.
• Figure 40 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer alternative approach parameter analysis.
• Figure 41 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer alternative approach function analysis.
• Figure 42 is a visual display screen illustrating a display screen for inputting data and displaying feature transfer alternative approach element analysis.
• Figure 43 is a visual display screen illustrating a display screen for inputting data
• Figure 44 A - E are representations of EAS trimming rules.
• Figure 45A is a flow diagram of the major sub-sessions or stages of the PSA system.
• Figure 45B is a flow diagram of the major routines of the Process Analysis stage of Figure 45 A.
• Figure 46 is a block diagram of the PSA system.
• Figure 47 is a PSA visual device screen illustrating a display for entering data and displaying initial PSA project data.
• Figure 48 is a PSA visual device screen illustrating a display for entering data and displaying initial PSA team member and project data.
• Figure 49 is a PSA visual device screen illustrating a display for entering data
• Figure 50 is a PSA visual device screen illustrating a display for entering data
• Figure 51 A is a PSA visual device screen illustrating a display for entering data
• Figure 5 IB is similar to Figure 51 A for entering and displaying Function data.
• Figure 52 is a PSA visual device screen illustrating a display for entering data
• Figure 53 is a PSA visual device screen illustrating a display for entering data and displaying function type and other function data.
• Figure 54 is a PSA visual device screen illustrating a display for entering data
• Figure 55 is a PSA visual device screen illustrating a display for entering data and displaying function type and other function data.
• Figure 56 is a PSA visual device screen illustrating a display for entering data and displaying Link Analysis data.
• Figure 57 is a PSA visual device screen illustrating a display for entering data and displaying Link Analysis significance data.
• Figure 58 is a PSA visual device screen illustrating a display for entering data and displaying Function Rank data.
• Figure 59 A is a PSA visual device screen illustrating a display for entering data and displaying Problem Rank data.
• Figure 59B is a PSA visual device screen illustrating a display for entering data and displaying cost of each Operation.
• Figure 60 is a PSA visual device screen illustrating a display for entering data
• Figure 61 is a PSA visual device screen illustrating a display for entering data
• Figure 62 is a PSA visual device screen illustrating a display for entering data and displaying Trimming conditions data including function transfer.
• Figure 63A is a PSA visual device screen illustrating a display for entering data and displaying Trimming conditions data including Trimming data.
• Figure 63B is a PSA visual device screen illustrating a display for entering data and displaying Trimming conditions data including Trimming data.
• Figure 64 is a PSA visual device screen illustrating a display for entering data and displaying Trimming conditions data including dropping an action data.
• Figure 65 is similar to Figure 51 A and 5 IB illustrating the modified and improved process model with functions transferred, trimmed, and modified.
• Figure 66 is a PSA visual device screen illustrating a display for entering data and displaying Problem Manager including problem statements and problem significance data.
• EAS 10 resides on a personal computer 12 that includes a CPU 14, monitor 16, keyboard, mouse 18. and printer 20.
• the EAS program may be stored on a portable disk and inserted in disk reader slot 22.
• Computer 12 can be conventional and be of any suitable make or brand. However, minimum performance specification for computer 12 should be Intel 486 with 20 meg Hard Disk available, 4 meg of RAM, 75 MH clock speed. If paper copy of the EAS session is desired, printer 20 should also be provided. Other peripherals and modem/network interfaces can be provided as desired.
• an EAS session has four main
• the user starts a new session by accessing the EAS.
• the EAS prompts the user to enter
• the user can enter initial data with use of the keyboard and/or
• Report unit 215 functions to display elements of the final report on
• Report generator 210 coordinates the project objectives and rank with model data unit 190 and processes the model
• the user draws a symbol such as a box to represent each component of the object
• Boxes and lines can be labeled on screen and marked as useful or harmful as determined by the user.
• Supersystems, products, and their links with specific components are also drawn on screen.
• the model data unit 190 will input data to the graph unit 100 and once the entries to table unit 120 are complete,
• graph unit 100 will automatically draw the functional model for the user.
• the user can edit any data of the functional model in either the graph unit 100 or table unit 120 format.
• Model data unit 190 is a data storage facility and obtains and feeds data to the many
• the user calls up a link analysis unit 140 as part of the Functional
• This unit 140 enables the user to select for each link in the functional model a short description of the action link, such as compress, move, heat as well as its characteristic
• the user can, for any link, implement an advanced link analysis routine in advanced link
• model data unit 190 This advanced link analysis unit 130 enables four different types
• Parameter Value data can be represented either as qualitative relative ratio values or as
• the actual PSI and required PSI values can be entered in unit 130.
• the actual and required PSI values can be entered in unit 130.
• desired tolerances can be entered such as +2 psi and ⁇ 1 psi, respectively.
• the Time Dependency data is entered to unit 130 by the user selecting the actual and
• Space Dependency data is
• unit 130 by the user selecting the actual and required parameter value at various points in the space or distance through which the action occurs. Lastly, the user enters into unit
• Trimming is a routine for elimination or simplifying a component or action from an
• An object system usually includes harmful actions or useful actions which are not
• the EAS Trimming routine provides analyses for the redistribution of functions and elimination of components from an object system while retaining the components useful
• the first component becomes simpler and less costly.
• the object structure becomes more optimal and uniform.
• Trimming conditions are methods of redistributing the useful functions of an eliminated
• a component can be eliminated if:
• the EAS enables the user to:
• EAS Trimming routine provides two procedures for choosing an element to trim:
• Open choice of component allows the user to choose the component based on the component statistics, analyze the information given by EAS and recommend a decision as to
• Figure 44 A-E shows various EAS rules for elimination
• EAS creates a graph to illustrate its calculations.
• EAS places the component with the highest
• Function, Problem Rank, Task Significance (TS) Evaluation routine unit 220 accepts this data from unit 240. Unit 220 also receives constantly the Functional Model Data from unit 190. Unit 220 calculates and determines the EAS Functional
• Unit 250 calculates the EAS functional contribution of each component as a percentage relative to
• unit 250 determines the ranks of candidacy for trimming (elimination) and represents its recommendation
• the component trimming candidacy rank can be represented by a dot on the graph located anywhere in or on the line between any of four quadrants A-D as described below.
• the Integrated Component Evaluation routine is seen in Figure 7. Problem rank from unit 220 is entered to unit 430. The user enters the component cost in unit 440 through unit
• EAS unit 250 sorts all components in the object system in accordance with the following table.
• the unit 250 then recommends to the user ranked components for trimming first from D group, than from C, B, A. If there are several components inside one quadrant, EAS unit 250 suggest
• This information is represented on screen at unit 255 and enables the user to edit the F,
• Unit 270 analyzes the action between two components one of which is to be trimmed and suggests another component to which the trimmed function might
• This recommendation can be edited by the user or accepted or represented
• Every object system interacts with a supersystem or product.
• the graphic or table representations of the functional model will display one or a chain of components and links or interactions.
• the component linked to the product or supersystem has the highest rank and the component furthest from the product or supersystem has the lowest rank. If a component performs several useful actions (such as a piston that both compresses and functions as a valve)
• the function rank will be calculated as the sum of the action ranks. Harmful actions are ignored in calculating function rank.
• Task Significance is automatically calculated in a subroutine of unit 220.
• the result of this calculation is termed Action Task Significance, see Figure 4.
• each action can be described by several parameters entered by the user, namely Value TS 350, Time Dependency TS 360, Space Dependency TS 370, and Parameter Dependency 380.
• Value TS Value TS 350
• Time Dependency TS 360 Time Dependency TS 360
• Space Dependency TS 370 Space Dependency 370
• Parameter Dependency 380 Parameter Dependency 380.
• the user can select to enter qualitatively through Qualitative VTS (Value TS) unit 390 or quantitatively through Quantitative VTS (Value TS) unit 400.
• the calculation by unit 350 of Value TS is provided in accordance with the following formula:
• VTS - value task significance k j - coefficient of objective importance (If problem is associated with objective, that has high importance, value of coefficients high); V r - required value of parameter V a - actual value of parameter TV r - admissible deviation of required value.
• DTS - dependency task significance (the formula is similar for all kinds of dependencies); k j - coefficient of objective importance (If problem is associated with objective, that has high importance as entered by user in Initial Data stage, value of coefficient is high); D ri - value of i-point of required dependency for parameter; D ai - value of i-point of actual dependency for parameter; ID r - admissible deviation of required dependency; 11 - number of point.
• VTS *, ⁇ V ac - V furnish ⁇ ⁇ v ac
• VTS - value task significance k j - coefficient of objective importance (If problem is associated with objective, that has high importance, value of coefficient is high);
• Unit 220 also includes a subroutine for calculating the action Problem Rank (P), see Figure 5.
• Problem rank is calculated in accordance with the following formula:
• This Trimmed Model data is modified by or edited by the results data
• Unit 280 applies trimmed model data to Report Generator 210 that generates
• Trimming Results data applies it to Report Unit 160 that presents it on screen to the user.
• unit 210 receives and processes both the Model Data from unit 190 and the Trimmed
• These characteristics can include, for example, the number of components in the session
• object system number of harmful actions, total component costs, number of links, number of useful actions, and useful action components.
• the EAS automatically formulates and retrieves one or more components from the session object.
• Problem Manager routine unit 150 enables the user to input data related to the functional model
• the problem Manager unit 150 prompts
• Each component and action of the functional model is
• Problem Manager data is stored in Problem Data
• PM Problem Management
• the Problem Manager routine also aids the user in evaluating different designs of the
• unit 150 and unit 230 include a Feature Transfer: Object Data prompt
• Unit 230 processes the trimmed model data
• F,P,TS data, and problem data calculates an index or quantitative ranking number for each design model and recommends one of the component design models for analysis
• Unit 230 also generates a Feature Transfer: Recommendation on how to begin the problem solution. For example, a piston
• the unit 230 recommends to the user to define the technical effect that enabled the leakage resistance to be improved in the alternate piston. If the user needs help in considering a
• the user can select a box that will represent on screen a number of technical effects related to pistons and select the one that contributed to the better parameter achievement by the alternate piston.
• the unit 150 then formulates the
• the technical problem solving module can be the above mentioned Invention Machine Software.
• Problem Manager routine unit 230 can process two
• action problem 1 - problems related to actions between elements
• Action problems are processed in unit 230 using the Action TS data from unit 220 as described above. Trimming problems are identified or connected with a trimmed component.
• the user chooses one of the trimming conditions through unit 150.
• unit 230 calculates the sum of the problems of I group associated with the component (box 420) and generates a new problem of action transfer with significance equal to this sum (box 420).
• a session begins with EAS prompting the user to enter certain basic information into a Project
• the EAS will prompt the user to optionally enter detailed objectives such as the unit of measurement, the current value, the desired value, and whether the value should increase or decrease as a session objective.
• This Project Data field provides a list of possible objectives and limitations. The user may select the items from this list which apply to the current project. This list may also be customized by the user using add and remove buttons. Each of the categories for the objectives and limitations should be ranked according to their importance. EAS will use this ranking later when it calculates which problems are most urgent and which components can be trimmed.
• team members are to work on the project, they can be listed in the team file, Figure 11 , and a final report can only be generated with the computer concurrence of all these members.
• the first step in using EAS to analyze an object system is to draw an object structure.
• the components parts of the object
• Each object system has a hierarchy and is decomposed into units; the units are decomposed into parts and so on. It is preferred to start the analysis on the highest level of the hierarchy. If necessary, EAS can analyze the lower levels of the hierarchy simply by breaking components into sub-components. The interaction of the object with the elements of the environment, products and supersystem elements, should also be shown.
• the EAS prompts the user to open a second file called Functional Model in which the user can input data and the EAS will display the object system functional model.
• the user can select a Graph mode Figure 12 or Expert step-by-step mode. In the graph mode, the
• the user enters all useful interactions between elements such as “compress” between piston image and water image and “direct” between the cylinder and piston images and “move” between the lever and piston images.
• the EAS enable the user to represent harmful effects of element interaction such as “clogging” between the dust and valve images and “corrode” between the supersystem air image and the cylinder image.
• the interactions can be represented in different colors such as blue or black for useful and red for harmful.
• the user can select the Expert mode and the EAS units 1 10 and 120 will initiate a routine to provide a series of dialog boxes in table form that leads the user through the data entry steps described above.
• This routine enables an alternate method of inputting the functional model data as described above.
• the first dialog box displayed for Expert is shown in Figure 27 in which the user can select a "basic” or detailed and advanced analysis or a "short” or less detailed analysis. If the short analysis, no information about harmful actions will be permitted by the EAS. but parameters, values and dependencies can be entered for useful actions.
• Figure 27 enables the user to enter the supersystem product or media with which the object system produces or interacts.
• the object system (pump) interacts with the product '"water" so water would be entered.
• the Expert routine displays a dialog box, Figure 28 calling for entry of additional syspersystem elements, such as air, dirt, or other environmental elements which interact with the object system. Each element is added to the dialog box by the user.
• the Expert routine displays a dialog box showing boxes arranged in a hierarchy, see Figure 29. The names of the object system and product and all other supersystems automatically appear in the top row of boxes. The user enters each major component in the next row of boxes and, if desired, each sub-component in the boxes below a component. All data in this dialog box can be edited as desired and previous screen data will be changed accordingly.
• the I level simply enables the EAS to analyze the level above the component level.
• the II level enables a first component level analysis and the III level enables all levels to be analyzed. See Figure 31.
• the Expert route next displays a legend of interaction among all components, elements and products and displays a legend of four interactions across the lower portion of the matrix. See Figure 32.
• the user can click on any intersection, box for X and Y entries, select any ones of the four interactions along the bottom and then click on one of the element names to save the interaction selections. These selected interactions will appear in the respective box intersection as shown in Figure 32.
• Interactions can be deleted (edited) from a box by clicking on one of the axis entry names, then clicking on the action to be deleted. All interactions within all boxes can be entered in the same way. Note the four interactions include "useful”, “useful insufficient”,”useful excessive *' and "harmful", each being associated with a different symbol or color, preferably red for harmful.
• Model Data unit 190 the user can click on Finish to save to Model Data unit 190 and click on Browser that displays the table of Figure 33.
• the user can enter each action name between each product, component, and/or supersystem and enter the Rank of interactions as harmful (H) or basic (B), auxiliary function rank A) A — A
• H harmful
• B basic
• auxiliary function rank A A
• This data is stored in unit 190 and at this point the functional model can be displayed by the EAS via unit 100, see Figure 12, and the user is ready to implement the Link Analysis and Advanced Link Analysis described below.
• the EAS will automatically draw the diagram of the object system as shown in Figure 12. It will be noted that more than one action can be entered between components, such as the three different actions shown in Figure 12 between "cylinder” and "piston".
• the EAS Functional Model can then prompt the user to perform a Link Analysis followed by an optional Advanced Link Analysis, so that each link or interaction between all elements are examined one at a time.
• the Link Analysis presents to the user the image of two elements and the selected link or interaction between them. See Figure 13 that shows the user data input capability for the analysis of the "compress" interaction between piston and water of the present session.
• the Link Analysis prompts the user to identify the link as harmful or useful, the level rank of the function of the interaction to the overall function of the object system. This Level includes the user choices Excessive, Normal, and Insufficient and represents
• the user If more detailed analysis of the link is desired, the user
• Advanced Link Analysis lists each parameter, e.g. "pressure”, and prompts the user to initiate
• Value screen prompts the user to indicate the qualitative or quantitative nature of the value and input the actual pressure value, the required pressure value plus or minus the tolerance. High, middle, or low significance of this value can
• the qualitative value can be selected and the user indicate actual and required pressure value by a relative slide button adjustment, see
• the EAS enters the Trimming Stage, Figure 3, by presenting the screen of Figure 20 in
• the Trimming: Parameter Evaluation screen, Figure 21 displays through unit 240 the Problem Rank for each component of the
• the EAS displays the Integrated Component Evaluation Table and/or graph of Figure 24 where each component has its Function and Problem + Cost rated as a percentage
• EAS assigns an A - D ranking or dot location on a 4-quadrant graph as shown.
• Each component can be highlighted for highlighting its dot on the graph while other dots for other components remain light. This display is
• the EAS next displays the Trimming Condition for the recommended or selected
• Trimmed component e.g. the valve and the possible trimming variant, e.g. the piston. See Figure 25, where the related action "control" is also selected. The transfer of this action to another component, and in this example, "control" of the cylinder is transferred to the action
• unit 260 in Figure 1 that applies this data to unit 270 as described above.
• Unit 270 then
• FIG. 26 shows the trimmed functional model generated from the data stored in unit 280.
• the valve box is drawn in phantom because it was eliminated and no interaction exists between valve and cylinder.
• EAS Problem Manager that automatically generates a list of problems to be solved.
• Problem Manager is a tool that helps the user browse through all the problems associated with the trimmed functional model and to sort them based on value priority. Since the number of problems can be rather large, EAS calculates their significance and sorts them accordingly.
• This table includes the problem Number assigned by Problem Manager, the significance generated by EAS of the problem, that is relative value if solved, the EAS generated group or type of problem solution objective and the team member responsibility to be entered by the user if desired.
• the star 26
• the EAS enables the user to search for problems associated with actions, components or supersystems of the functional model.
• Figure 34 shows "by element name"
• the EAS also includes a Feature Transfer routine that enables the user to analyze the best feature or functions or alternate elements or alternate systems and compare those desirable
• the first Feature Transfer screen, Figure 35 is displayed when Feature Transfer is selected from the "Tools" icon on the menu bar.
• the user enters the object or component to be analyzed such as piston 1 , 2 and 3 as shown.
• One of these, e.g. piston 2 may be the piston from the current object system under evaluation by the EAS.
• the other pistons may be from other known pump models.
• User then enters the important parameters 1 , 2, and 3 (or more),
• the objective column 30 enables user to indicate the increase or decrease objective for each
• Parameter units are entered by the user and the user enters the importance rank (10
• the Technological limit of a parameter is the value that the
• Theoretical limit of a parameter is the best value that the parameter could achieve
• the EAS Feature Transfer Routine analyzes the feature transfer data for piston 1, 2 and
• P j - parameter value that is calculated as a percentage of sum of all parameter values.
• Objects can be sorted by object number or index number by clicking the "Object" or "Index” box at the top of the column. User clicks next to get to the feature transfer recommendation screen, Figure 38. This screen provides short recommendations about how to
• Figure 39 On this screen the user can formulate several concepts using the alternative approach by first choosing the name of the concept from the Concept name list box. A short
• dialog boxes is displayed to lead the user through the steps of analyzing a solution in an
• Figure 40 asks which element(s) is responsible for leakage. User enters the name of the initial or current object system element "piston". To check the entry the user can note that if piston is trimmed, leakage is also deleted. There can be no leakage without a piston. Selecting next brings the Figure 41 display asking user to enter the element of the original object system that performs the function connected with leakage. Here the user entered “piston ring.” Selecting next displays a screen that
• Piston 2 in this example, used packing so user enters "packing" as the "element" in
• the EAS unit 210 can generate a report by organizing and managing the information from the various and predetermined subroutines in the
• a Report icon is displayed as part of the EAS navigation window and includes a "Generate" command that can be clicked to initiate the report.
• Parts of a report can be edited just as any word processing program can be edited.
• the EAS hereof can be programmed by one of ordinary skill in the art using the
• This specification The user accesses this Process System Analysis module when it is desired to analyze, design or redesign a manufacturing or treatment process, method or technique.
• the user starts a new session by accessing the EAS-Process System Analysis module.
• the Process System Analysis prompts the user to enter the first stage " nitial Data.”
• the user can enter initial data with use of the keyboard and/or mouse, such as project name, objectives, and objective ranking.
• Initial Data stage the user enters initial project data to the
• Report unit 217 functions to display elements of the
• Report generator 218 coordinates the project objectives and rank with model data unit 1 5 and
• the user inputs data to Component graph unit 410.
• Unit 410 serves to display a graphic representation of the Component Model of the Process System under analysis. The user draws a symbol such as a box to represent each Component of the Process System model and a line between boxes to represent each Component added and its
• Boxes can be labeled on screen and the
• Color coding can be used to designate which Components result from process Operations or which are simply added to the Process System. See Figure 49 which is
• Units 420 and 450 develop displays of the sequence of Operations (one or
• table unit also enables entry of a description of each Operation Function and the specification of
• the Functions such as a Functions action, source or tool, target object or Component class of function, such as, useful or harmful and type of useful Function contributing to the Operation,
• the Process System Analysis further includes a Function Link Analysis unit 440 that
• Model data unit 1 5 is primarily a data storage facility and obtains and feeds data to the
• This unit 440 enables the user to select for each link in the Operation Model a
• the user can, for any link, implement a more detailed link analysis that enables the user
• Parameter Value data can be represented
• the Time Dependency data is entered to unit 440 by the user selecting the actual and
• Space Dependency data is
• a Process System usually includes harmful operation Functions and useful operation
• each Function within each Operation had data entered, inter alia, including its action, element type and performance.
• the type of Function includes harmful and useful,
• the PSA also stores a value or score associated with a
• model data unit 195 are also stored in model data unit 195 and used in subsequent evaluation algorithms.
• routine enables the user to evaluate and determine which Functions and/or Operations, if trimmed would yield the greatest value toward the project objective.
• the PSA uses an operation evaluation algorithm to choose the recommended order in
• the algorithm uses standardized values of the problem rank (P),
• the evaluation unit 225 then generates a graph to illustrate its calculations.
• Model data unit 195 communicates continuously with F, P, C Evaluation unit 225 which
• Unit 225 then calculates the highest to lowest scores for each Operation and feeds this data to units 245, 195, and 235.
• Unit 245 plots and displays the operations on the graph and places the
• the criterion formula preferably, describes a set of parabolas
• PSA trimming recommendation for each Operation depends on where it falls on the graph. In the illustration
• the PSA would recommend trimming the Operation with the lowest function rank and highest problem rank and cost.
• the user can always quickly and visually analyze the
• the PSA enables the user to enter a customized trimming parameter or
• unit 245 presents a dialog box displaying the
• Unit 245 then feeds unit 225 for modifying the output thereof which is fed to unit 235.
• unit 225 If user enters no data to unit 245, the unit 225 output is fed unmodified to unit 235 and
• Unit 255 data is also fed to unit 275 where the trimming condition is evaluated.
• User can interact and modify the Process System Analysis object structure through unit 265.
• the PSA displays the screen of
• Figure 47 prompts user to enter the Project Name, Process identity and present Process description. One or more Objectives must be entered. In this example, the user is presented with
• Figure 50 table prompts user to enter one or more operation steps currently used to make the highlighted component.
• user entered in the first column in proper numbered sequence, Cutting, Heat Treatment and Finishing.
• the PSA automatically designates the next columns the same as the Parameter objective row headings from initial data screen Figure 47, i.e., Energy Consumption (kw) and Operation Time (min.) and enables user to enter the present values for each operation step.
• Similar data is entered for the other component (Gear) in the assembly and for the Assembly Unit which would include steps, energy and time necessary to assemble the components as a unit.
• Function tab of Figure 50 in response to which the PSA displays the screen of Figure 51.
• the PSA enables user to break down broad operation steps into more detailed specific actions, the specific tools used to perform action, and the element of the component acted upon.
• the action is ranked into one of 4 categories (Productive; Providing; Corrective; and Harmful) and its performance effect or value indicated.
• the upper part includes the three steps in forming the shaft: 1.1 Cutting, 1.2 Heating and 1.3 Finishing. These operation steps also appear in the table in the lower portion with the columns headed as mentioned above.
• the user highlights the component, i.e. Shaft, that brings up the two tables depicted but without any data other than the three operation steps Cutting, Heat Treatment and Finishing as described above.
• User selected “spindle” which appears in row 1.
• user enters the action "rotate” in the next column and selects "shaft " as the element receiving the action ort acted upon by the spindle.
• the action is ranked by type.
• PSA also displays the pertinent data in the upper chart of Figures 51 A and 5 IB and stores the
• the PSA responds by displaying the screen in Figure
• PSA displays a graphic to the right which shows the object of the function (shaft) and the
• spindle rotates shaft is not associated with Heat Treatment or
• Figure 52 can be provided in Figure 52 screen which, when selected, immediately causes screen Figure 53 to appear.
• screen Figure 53 can appear when the "OK” button is selected in screen Figure 52. Whenever an "OK" button is selected, the user entered data is stored or processed by the PSA as described above.
• the PSA highlights Productive for the function Cutter Removes Metal. No box on the right side can be checked because this function is the ultimate objective of the operation step, i.e. the Productive characteristic was designated for this function as described above.
• screen Figure 54 is displayed with Harmful type highlighted, e.g. appearing in red.
• Harmful type e.g. appearing in red.
• the user can select no box under Heat Treatment because the action is designated harmful. User simply clicks 'OK" and moves on.
• Air Oxidize Shaft Figure 55
• the PSA also clicks Heat Treatment operation step as receiving the correction.
• the other logic link arrows are generated and displayed by the PSA as shown at the top portion of Figure 51.
• the user can initiate the Link Analysis substage by clicking on the right most icon 456 for a specific function in Figure 51.
• the PSA displays a Link Analysis screen for each function of each operation selected.
• the PSA prompts user to enter in graphic form the actual and required behavior of a
• Figure 56 shows the Link Analysis screen for the function Inductor Heats Shaft (1.2.2).
• User designated “temperature” as a “useful” action and checked '"time” as the dependency.
• the PSA displayed two graphics labeled “Actual” and “Required” behavior with all points (small circles) lying on the time axis. User then uses the cursor to move points (shown as small circles) to estimated vertical positions above the "time" axis to display and enter data of the actual and
• the PSA also enables entry of the significance factor for the temperature behavior and the acceptable deviation on a slide bar.
• the difference between the under-curve areas of the two graphs is calculated by PSA and also dispOlayed, for example 8.0 in Figure 56.
• the PSA displays the values. Note the scale reads from, in this example, zero to 2 in the direction of the objective ("Down”). If an objective were shown having an "Up” designation, the zero for it would be on the left and the 2 on the right of the marker scale.
• the PSA acquires the readings of all rows (in this example, two rows) and calculates the significance which, for screen Figure 57, is 6.0 using the algorithm as shown thereon. Note
• the PSA Upon entering Trimming Stage, the PSA first displays an Operation Evaluation Screen
• Figure 58 which prompts each team member to rank each operation on a 10-1 scale for:
• Cost Actual or allocated cost in Dollars for the operation.
• each team member entered his/her estimated function and problem ranks. If desired, the system can be configured so that each team member can see displayed only the ranking data he/she entered
• the PSA calculates the average and displays the results in the right hand columns of the screen. Each team member views the results, speaks with the other team members and makes modifications to his own evaluation as desired. In this case, the PSA will process the average of the various evaluations.
• FIG. 60 The purpose of this screen is to display a number of Operations in possible (PSA).
• the Trimming Factor value for each operation defines a specific
• the PSA recommends Trimming or improving Heat Treatment (1.2) to yield the greatest value toward the entered project objectives.
• the PSA in this screen, presents a recommended list, in rank order of value, of
• PSA generates this list by applying the algorithm
• the PSA will evaluate and recommend possible trimming conditions for overall process
• the Trimming Routine has access to previous stage data and also stores a set of
• the PSA Trimming Routine automatically lists (parses) the stored Operations in
• the PSA also analyzes logic links (Corrective, Providing) between functions and in
• the PSA displays in rank order the four trimming/transfer possibilities with the best (first on list) possibility or condition automatically
• Figure 62 also displays the graphic Operation, "Cutting", to which Operation the PSA
• the PSA greatly enhances the user's ability to analyze
• PSA displays the next important recommendation, i.e.. "remove slag" from the Finishing Operation.
• the PSA stored data indicating that "remove
• Figure 65 is generated from data stored for Figures 51 A and 5 IB and Figures 62A through 64 and confirmed when user
• the PSA displays Figure 66 which lists the problems to be solved in achieving a better, modified process.
• the PSA clearly lays out the problems on the right side of Figure 66.
• On the left specific actions are listed along with the Problem Significance of each action generated by PSA from stored input data described above. Note the action with the highest significance (value) is "heat shaft transfer" with 83.0 compared to the others in the present example.
• PSA advises user that solving the problem of how to transfer "heat shaft"
• PSA provides a powerful tool enabling the user to undertake extensive, automatic process
• Manufacturing Process a model of an engineering system which reflects the nature
• Function action of a material object that changes the parameters of another material object.
• Carrier of the Function an object that performs the function
• Object of the Function a material object that the action of the considered function is
• Function Type Characteristic of a function that reflects specific changes introduced into the
• Function of Operation a function executed within the framework of a given operation.
• Useful Function a function that satisfies the requirements of the user of the function carrier.
• Productive Function a useful function that permanently changes the parameter(s) of the
• Providing Function a useful function that temporarily changes the parameter(s) of the object. This parameter change enables or facilitates subsequent or concurrent useful functions or operations. The temporary changes produced by providing functions are reversed by corrective
• Corrective Function a useful function that changes the parameter(s) of the object to eliminate
• This parameter change may reverse the changes of a providing
• Harmful Function a function that worsens the parameter(s) and/or performance of an object.
• Parameter descriptions of properties in terms of measure or quality or characteristic.
• Useful Action an action performing a useful function.
• Harmful Action an action performing a harmful function.
• Normal Intensity a situation when the actual intensity coincides with the required one.
• Insufficient Intensity a situation when the required intensity exceeds the actual one.
• PARAMETERS OF ACTIONS (VALUES AND DEPENDENCIES): Useful: Actual Value: the value of a parameter at a point in its life cycle.
• Required Value a value that a parameter should have for optimal performance of its corresponding function(s).
• Acceptable Deviation indicates the acceptable limits of the required value.
• Acceptable Value Value that provides an acceptable level of damage for the object.
• Ideal value value that provides absence of damage to the object.
• Trimming a method of improving manufacturing process based upon the elimination of
• Trimming Conditions the various options available for redistributing useful functions.
• Goals of Trimming the problem to be solved to realize the chosen trimming conditions.

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• 1999
  • 1999-02-08 US US09/245,669 patent/US6202043B1/en not_active Expired - Lifetime
• 2000
  • 2000-01-27 WO PCT/US2000/002067 patent/WO2000046703A1/en active Application Filing
  • 2000-01-27 AU AU29739/00A patent/AU2973900A/en not_active Abandoned
  • 2000-01-27 EP EP00908391A patent/EP1208484A4/en not_active Withdrawn

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