초록 ▼

A method for batch control in a system. The system comprises at least two batch processing sets that share at least one shared equipment. A batch is initiated in each processing set. Process variables from each batch are monitored. At least one process variable from at least one batch are adjusted u

A method for batch control in a system. The system comprises at least two batch processing sets that share at least one shared equipment. A batch is initiated in each processing set. Process variables from each batch are monitored. At least one process variable from at least one batch are adjusted using bang-bang control to prevent conflicts.

대표청구항 ▼

1. A batch control method for producing chips utilizing bang-bang control to avoid a conflict over a first piece of shared equipment in a system, wherein said first piece of shared equipment is used by at least two batch processes for making chips, wherein said bang-bang control comprises adjusting

1. A batch control method for producing chips utilizing bang-bang control to avoid a conflict over a first piece of shared equipment in a system, wherein said first piece of shared equipment is used by at least two batch processes for making chips, wherein said bang-bang control comprises adjusting at least one process variable between at least two states to provide at least one adjusted process variable and to obtain a desired process condition, wherein said adjusting prevents a conflict in said system, said conflict arising when at least two batch processes simultaneously require a first piece of shared equipment, said system comprising: a first batch processing set comprising a first kettle and said first piece of shared equipment;a second batch processing set comprising a second kettle and said first piece of shared equipment; anda controller;said method comprising:a. starting a first batch process for producing chips in said first batch processing set, introducing a first material for said first batch process in said first batch processing set, and cooking said first material in said first kettle to produce chips;b. starting a second batch process for producing chips in said second batch processing set, introducing a second material for said second batch process in said second batch processing set, and cooking said second material in said second kettle to produce chips;c. utilizing said controller in monitoring at least one process condition on said first batch process to provide a first set of monitored process conditions and utilizing said controller in monitoring at least one process condition on said second batch process to provide a second set of monitored process conditions;d. utilizing said controller in adjusting said at least one process variable to provide said at least one adjusted process variable and to obtain said desired process condition, thereby preventing said conflict;wherein said first piece of shared equipment is selected from the group consisting of a pump, an agitator, a conveyor, a slicer, and a heat exchanger;wherein said first set of monitored process conditions comprises a process condition selected from the group consisting of a temperature, a time, a rate of heating, a rate of cooling, a fluid flow rate, a duty of a burner, a duty of a heat exchanger, a percent conversion, and an intermediate chip property;wherein said second set of monitored process conditions comprises a process condition selected from the group consisting of a temperature, a time, a rate of heating, a rate of cooling, a fluid flow rate, a duty of a burner, a duty of a heat exchanger, a percent conversion, and an intermediate chip property;wherein said at least one adjusted process variable comprises a process variable on a batch process selected from the group consisting of said first batch process and said second batch process;wherein said at least one adjusted process variable comprises a process variable selected from the group consisting of a rate of heating, a rate of cooling, a fluid flow rate, a duty of a burner, a duty of a heat exchanger, and a temperature; andwherein said desired process condition selected from the group consisting of a desired temperature, a desired separation time, a desired batch processing time, a desired total batch time, a desired batch finish time, a desired rate of heating, a desired rate of cooling, a desired duty of a burner, a desired duty of a heat exchanger, a desired percent conversion, a desired intermediate chip property, and a desired final chip property. 2. The method of claim 1 wherein said at least one adjusted process variable comprises a rate of heating a kettle selected from the group consisting of said first kettle and said second kettle. 3. The method of claim 1 wherein said at least one adjusted process variable comprises a process variable selected from the group consisting a gas flow rate to a kettle heater and a liquid flow rate to a kettle heater. 4. The method of claim 1 wherein said at least one adjusted process variable comprises a gas flow rate to a kettle heater. 5. The method of claim 1 wherein said first set of monitored process conditions comprises a process condition selected from the group consisting of a gas flow rate to a kettle heater, a liquid flow rate to a kettle heater, a temperature, a current batch processing time, a calculated separation time between starting a subsequent batch process in said first batch processing set and starting a subsequent batch process in said second batch processing set, a calculated batch finish time, and a calculated total batch time; and wherein said second set of monitored process conditions comprises a process condition selected from the group consisting of a gas flow rate to a kettle heater, a liquid flow rate to a kettle heater, a temperature, a current batch processing time, a calculated separation time between starting a subsequent batch process in said first batch processing set and starting a subsequent batch process in said second batch processing set, a calculated batch finish time, and a calculated total batch time. 6. The method of claim 5 wherein said first set of monitored process conditions comprises a process condition selected from the group consisting of a temperature, a calculated separation time between starting a subsequent batch process in said first batch processing set and starting a subsequent batch process in said second batch processing set, a calculated batch finish time, and a calculated total batch time; and wherein said second set of monitored process conditions comprises a process condition selected from the group consisting of a temperature, a calculated separation time between starting a subsequent batch process in said first batch processing set and starting a subsequent batch process in said second batch processing set, a calculated batch finish time, and a calculated total batch time. 7. The method of claim 6 wherein said first set of monitored process conditions comprises a temperature of said first kettle and an associated point in time, and said second set of monitored process conditions comprises a temperature of said second kettle and an associated point in time; wherein said at least one adjusted process variable comprises a fluid flow rate to a heater for a kettle selected from the group consisting of said first kettle and said second kettle; andwherein said desired process condition in step d comprises a desired batch processing time for a batch process selected from the group consisting of said first batch process and said second batch process. 8. The method of claim 6 wherein said first set of monitored process conditions comprises a temperature profile of said first kettle over time, and said second set of monitored process conditions comprises a temperature profile of said second kettle over time; wherein said at least one adjusted process variable comprises a fluid flow rate to a heater for a kettle selected from the group consisting of said first kettle and said second kettle; andwherein said desired process condition comprises a desired batch finish time for a batch process selected from the group consisting of said first batch process and said second batch process. 9. The method of claim 1, further comprising the steps: starting a subsequent batch process in said first batch processing set to provide a first subsequent batch process;starting a subsequent batch process in said second batch processing set to provide a second subsequent batch process;wherein said desired process condition comprises a desired separation time, wherein said desired separation time is a difference in time between said starting said first subsequent batch process and said starting said second subsequent batch process. 10. The method of claim 9, wherein said desired separation time is about half of a batch processing time for said first subsequent batch process. 11. The method of claim 1 wherein said first batch processing set comprises a frying kettle. 12. The method of claim 1 wherein said at least one monitored process condition of step c) comprises a temperature of said first kettle and a temperature of said second kettle. 13. The method of claim 1 wherein said process condition of step c) comprises processing time. 14. The method of claim 1 wherein said process condition of step c) comprises separation time. 15. The method of claim 1 wherein said process condition of step c) comprises calculated total batch time. 16. The method of claim 15 wherein said adjusting of step d) comprises adjusting the total batch time of at least one batch process. 17. The method of claim 15 wherein said adjusting of step d) comprises adjusting the total batch time of at least one batch process, wherein the processing time of the batch process is not adjusted. 18. The method of claim 15 wherein said adjusting of step d) comprises adjusting the recovery time. 19. The method of claim 1 wherein said adjusting of step d) results in extending a total batch time of a batch process selected from the group consisting of the first batch process and the second batch process. 20. The method of claim 1 wherein said desired process condition of step d) comprises a desired batch processing time, wherein said batch processing time is the time elapsed from start to completion of a batch process. 21. The method of claim 1 wherein said at least one adjusted process variable of step d) comprises a gas flow rate. 22. The method of claim 1 wherein said adjusting of step d) comprises decreasing a gas flow rate. 23. The method of claim 1 wherein said starting said second batch process occurs after said starting said first batch process so that said second batch process is out of phase with said first batch process. 24. The method of claim 1 wherein said adjusting step consists of adjusting at least one process variable on only one of said batch processes. 25. The method of claim 1 wherein said adjusting step comprises adjusting at least one process variable on both said first and second batch processes. 26. The method of claim 1 wherein said system further comprises a third batch processing set comprising said first piece of shared equipment; wherein said method further comprises step e) of starting a third batch process in said third batch processing set; and wherein said method further comprises each of said first, second and third batch processes utilizing said first piece of shared equipment at different times. 27. The method of claim 1 wherein said utilizing bang-bang control comprises adjusting said at least one process variable between only two states. 28. The method of claim 1 wherein said at least two states comprise an off state and an on state. 29. The method of claim 1 wherein said utilizing bang-bang control comprises adjusting said at least one process variable between more than two states.