# US 11,112,782 B2 · Process anomalous state diagnostic device and process anomalous state diagnosis method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,112,782 B2 - Document ID: US11112782B2 - Status: Granted - Kind: B2 - Application number: 16/624,677 - Filed: 2018-06-19 - Published: 2020-04-09 - Granted: 2021-09-07 - Earliest claimed: 2017-06-19 - Assignees: Jfe Steel Corporation - Applicants: Jfe Steel Corporation - Inventors: Takehide Hirata - Web page: https://patentgrep.com/patent/US11112782B2 ## CPC - G05B 23/024: {Quantitative history assessment, e.g. mathematical relationships between available data; Functions therefor; Principal component analysis [PCA]; Partial least square [PLS]; Statistical classifiers, e.g. Bayesian networks, linear regression or correlation analysis; Neural networks} - G05B 23/0281: {Quantitative, e.g. mathematical distance; Clustering; Neural networks; Statistical analysis} - B21B 38/00: Methods or devices for measuring, {detecting or monitoring} specially adapted for metal-rolling mills, e.g. position detection, inspection of the product {(control devices or methods B21B37/00)} - G05B 23/0254: {based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks} - G05B 23/0272: {Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user} - G06Q 10/00: Administration; Management - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - B21B: ROLLING OF METAL (auxiliary operations used in connection with metal-working operations covered in B21, see B21C; bending by rolling B21D; manufacture of particular objects, e.g. screws, wheels, rings, barrels, balls, by rolling B21H; pressure welding by means of a rolling mill B23K20/04) - G06Q: INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR ## Abstract A process anomalous state diagnostic device configured to diagnose an anomalous state of a process based on deviation indexes for the magnitude of deviation from a reference that is a normal state of the process includes: a color mapping unit configured to configure a two-dimensional matrix that has a first axis as an axis of a temporal factor including time and that has a second axis as an axis of an item of each deviation index, associate each cell of the matrix with data for an item of the deviation index and the temporal factor, and allocate a color in accordance with the magnitude of the deviation index to each cell of the matrix; and a color map display unit configured to display a color map produced by the color mapping unit. ## Claims ### Claim 1 A process anomalous state diagnostic device configured to diagnose an anomalous state of a process based on deviation indexes for a magnitude of deviation from a reference that is a normal state of the process, the process anomalous state diagnostic device comprising: a color mapping unit configured to configure a two-dimensional matrix that has a first axis as an axis of a temporal factor including time and that has a second axis as an axis of an item of each deviation index, associate each cell of the matrix with data for an item of the deviation index and the temporal factor, and allocate a color in accordance with the magnitude of the deviation index to each cell of the matrix; and a color map display unit configured to display a color map produced by the color mapping unit. ### Claim 2 (depends on 1) The process anomalous state diagnostic device according to claim 1, further comprising a deviation index calculation unit configured to select variables indicating the state of the process and calculate the deviation index based on the difference between a prediction value by a prediction model that predicts an actual value of each selected variable and the actual value. ### Claim 3 (depends on 1) The process anomalous state diagnostic device according to claim 1, wherein the deviation index is a physical quantity including a vibration value or a temperature value of a facility included in the process and indicating soundness of the facility. ### Claim 4 (depends on 1) The process anomalous state diagnostic device according to claim 1, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each predetermined interval on the first axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a first pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 5 (depends on 2) The process anomalous state diagnostic device according to claim 2, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each predetermined interval on the first axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a first pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 6 (depends on 3) The process anomalous state diagnostic device according to claim 3, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each predetermined interval on the first axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a first pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 7 (depends on 4) The process anomalous state diagnostic device according to claim 4, wherein the color mapping unit is configured to collect each cell of the matrix for each batch processing in the process. ### Claim 8 (depends on 5) The process anomalous state diagnostic device according to claim 5, wherein the color mapping unit is configured to collect each cell of the matrix for each batch processing in the process. ### Claim 9 (depends on 6) The process anomalous state diagnostic device according to claim 6, wherein the color mapping unit is configured to collect each cell of the matrix for each batch processing in the process. ### Claim 10 (depends on 1) The process anomalous state diagnostic device according to claim 1, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each item of the deviation index on the second axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a second pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 11 (depends on 2) The process anomalous state diagnostic device according to claim 2, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each item of the deviation index on the second axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a second pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 12 (depends on 3) The process anomalous state diagnostic device according to claim 3, wherein the color mapping unit is configured to configure a matrix having a hierarchical structure including plurality of layers by collecting each cell of the matrix for each item of the deviation index on the second axis, associate a collective value of collected deviation indexes to each cell on each layer of the matrix, and allocate a color in accordance with the magnitude of the collective value of the deviation indexes to each cell on each layer of the matrix, and the color map display unit is configured to display, when a second pointer operation is performed on a cell of a color map corresponding to the matrix at a certain layer, a color map corresponding to the matrix one layer lower than the certain layer. ### Claim 13 (depends on 10) The process anomalous state diagnostic device according to claim 10, wherein the color mapping unit is configured to collect each cell of the matrix for each property of the deviation index. ### Claim 14 (depends on 11) The process anomalous state diagnostic device according to claim 11, wherein the color mapping unit is configured to collect each cell of the matrix for each property of the deviation index. ### Claim 15 (depends on 12) The process anomalous state diagnostic device according to claim 12, wherein the color mapping unit is configured to collect each cell of the matrix for each property of the deviation index. ### Claim 16 (depends on 13) The process anomalous state diagnostic device according to claim 13, wherein the property of the deviation index is a sub process included in the process or a physical quantity indicating the state of the process. ### Claim 17 (depends on 14) The process anomalous state diagnostic device according to claim 14, wherein the property of the deviation index is a sub process included in the process or a physical quantity indicating the state of the process. ### Claim 18 (depends on 15) The process anomalous state diagnostic device according to claim 15, wherein the property of the deviation index is a sub process included in the process or a physical quantity indicating the state of the process. ### Claim 19 (depends on 1) The process anomalous state diagnostic device according to claim 1, further comprising an information display unit configured to associate each cell of the matrix with a corresponding condition of the process and to display the value of the deviation index and the condition of the process corresponding to the cell in a separate window when a third pointer operation is performed on the cell. ### Claim 20 (depends on 1) The process anomalous state diagnostic device according to claim 1, further comprising a relevant graph display unit configured to associate each cell of the matrix with a temporal sequence chart of the corresponding deviation index or a scatter diagram of variables specified for each corresponding deviation index and to display the temporal sequence chart or the scatter diagram corresponding to the cell in a separate window when a fourth pointer operation is performed on the cell. ### Claim 21 (depends on 19) The process anomalous state diagnostic device according to claim 19, further comprising a relevant graph display unit configured to associate each cell of the matrix with a temporal sequence chart of the corresponding deviation index or a scatter diagram of variables specified for each corresponding deviation index and to display the temporal sequence chart or the scatter diagram corresponding to the cell in a separate window when a fourth pointer operation is performed on the cell. ### Claim 22 An anomalous state diagnosis method for a process of diagnosing an anomalous state of a process based on deviation indexes for a magnitude of deviation from a reference that is a normal state of the process, the anomalous state diagnosis method comprising: a color mapping step of configuring a two-dimensional matrix that has a first axis as an axis of a temporal factor including time and that has a second axis as an axis of an item of each deviation index, associating each cell of the matrix with data for an item of the deviation index and the temporal factor, and allocating a color in accordance with the magnitude of the deviation index to each cell of the matrix; and a color map display step of displaying a color map produced at the color mapping step.