AI Product Solutions

Three ways that AI can offer value in plants.

We’ve been working on solving a variety of customer issues. Of the issues that couldn’t be solved with conventional analysis methods, we were able to solve 50 by applying AI. We learned that in plants AI can offer value in the following three ways.

Abnormal Sign Detection

Predicts various equipment failures and plant shutdowns. Enables you to perform maintenance before an abnormality occurs, take countermeasures in advance, and improve your uptime.

Root Cause Analysis

Ascertains the causes of previous problems, and identify the cause of reduced quality and changes in consumed power. By identifying the areas of focus when improving and implementing quality measures, you can improve product quality.

Quality Estimation

Assigns quality indexes, predicts quality before testing, and predicts changes in quality. Get a handle on quality without destructive testing and other processes that take time to test, and reduce costs.

Results from YOKOGAWA AI solutions

These are some of the analysis results from AI solutions that YOKOGAWA has offered.
We have been solving customers’ issues in many industries including oil refineries and chemical plants using our AI.

Abnormal Sign Detection
-Quickly detects Anomality in equipment-

Results from YOKOGAWA AI solutions (Excerpt)

The above is only a small part.
See the AI Product Solution Book for other achievements.

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Utilizing our analysis experience and technology, we can offer a lineup of easy-to-use AI products.

In addition, we have prepared a video of an example of optimal plant control using AI reinforcement learning.
  → Please refer to Plant control by AI

Draw the past to the present, and on to the future
Now with the Future Pen
SMARTDAC+ GX/GP Series Paperless Recorders

AI is installed as standard, while maintaining the reliability and functions of the SMARTDAC+ GX/GP Series Paperless Recorders. With no complicated settings, you simply register the channels that you want to monitor as future pens, draw the near future as waveforms.

The GX/GP series is a panel mount or portable paperless recorder that provides intuitive touch panel operation. Its highly flexible modular I/O architecture enables you to acquire, display, and record data such as temperature, voltage, current, flow, and pressure in various industrial production and development sites.

Future Pen Demonstration for Predictive Detection

GX/GP AI functions

Future pen

Using acquired data to predict future data, draw predicted future waveforms along with real-time data on the trend monitor. The future waveforms allow you to identify and deal with likely problems.

Future alarm

You can set future alarms against future measured data from the future pen. Future alarm information is shown in a future alarm summary. When a future alarm is generated, external output or email give prior notice.

Examples of building recorder-centric AI solutions

Easily add AI to a recorder (GX/GP future pen, future alarm)

Process signals such as temperature and voltage can be displayed from past to present, and future waveforms by AI function. (GX/GP)

Accurate AI analysis in real time on a PC and displaying determination results on site. (GX/GP + GA10)

GX/GP collects the process signal and displays the measured values.
Send real-time data to PC, the AI analysis function of the software GA10 displays the result of AI judgment such as uncomfortable feeling detection on the GX/GP on the site side. 

Ask us about the highly accurate AI consultant service.

Analyze on an embedded device with accurate AI and display determination results (GX/GP + e-RT3 Plus)

GX/GP collects the process signal and displays the measured values.
Collects process signals with GX/GP, displays measured values, transmits data in real time to the Python-compatible AI platform e-RT3 Plus, and deploys the judgment results by the AI algorithm developed by the customer on the GX/GP screen can do.

Ask us about the highly accurate AI consultant service.

 
Please refer to the details of SMARTDAC+ SMARTDAC+ GX/GP Series Paperless Recorders
　> Panel mount type GX10/GX20  　> Portable type GP10/GP20

 

 

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AI on a stand-alone computer detects predictive abnormality sign of equipment
with Anomaly Detection,
AI analysis data logging software GA10 + Sushi Sensor

In recent years the need for maintenance is growing as equipment ages. Equipment conditions are mainly ascertained by human workers through inspections such as operator rounds inspection. However, we face the problems of declining birthrates leading to labor shortages, and the retirement of skilled workers leading to skill shortages. Also, the measured results obtained through an operator rounds inspections are not quantified, and often cannot be utilized effectively. We urgently need to create more efficient equipment maintenance mechanisms.

Automatically detects the “anomalies” that are signs of abnormalities

GA10 + Sushi Sensor are equipment predictive maintenance solution that is just like an AI operator, detecting the "anomalies" that are signs of abnormality, and automatically notifying the user.

You can dispatch worker to equipment that needs maintenance at just the right time, this reduces equipment inspection man-hours, lets you quickly discover abnormal signs, and prevents unanticipated equipment shutdowns. You realize more efficient equipment maintenance and increased plant availability.

*Sushi sensor: Up to 1000 units can be registered. (Gate Sushi function; option)

Predict the future with AI　New

GA10 Data Logging Software - AI notifies you of anomalies

*Sushi Sensor is to be released to other countries in order. For details, please click “more information”

Realize predictive maintenance and avoid future crises with the usual operability

 

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With a wealth of I/O for high scalability
and fan-less high environmental worthiness Supports Python
Industrial AI Platform e-RT3 Plus

Supports Python, which is indispensable for development of machine learning and other branches of AI, and you can add many AI open source libraries to quickly ramp up your AI development. Strong environmental worthiness, and ideal for industrial AI platforms that leverage the unique strengths of the e-RT3, with its easy access to I/O.

> Please refer to the details of e-RT3 Plus

High-Accurate AI using Python for industrial application in harsh environment

Reduce development time

Your existing AI applications stay as-is, with many fewer tedious I/O settings.

Environmental worthiness

The device used for development goes right into the harsh environment. Runs in environments where single-board computers couldn’t until now.

 

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The dream of an AI that can control your plant is becoming a reality.
-Plant control with AI and reinforcement learning-

Yokogawa has developed the technology to use AI to directly control equipment through reinforcement learning. 
Reinforcement learning is one type of machine learning in which AI learns from its own trial and error. The key feature of Yokogawa’s reinforcement learning technology making it so practical is that it can learn with a small number of trials. 

Application example:
AI control test equipment by a Three Tank Level Control System

Real-world sites often require complex control mechanisms. 
Here we show a experimental example of that, in which we apply reinforcement learning technology to control a Three Tank Level Control System. [Soundless video]

Three Tank Level Control System > Zoom

Result
In under 4 hours of learning, it found the ideal control method to eliminate the overshoots that occurred previously. 

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