Abstract: A system for detecting abnormal operation of at least a portion of a process plant includes a composite model for modeling at least the portion of the process plant. The model may be configurable to include multiple regression models corresponding to multiple different operating regions of the portion of the process plant. A new model may be generated from two or more of the regression models, and the composite model may be revised to replace the two or more regression models with the new model. The system may also include a deviation detector configured to determine if the actual operation of the portion of the process plant deviates significantly from the operation predicted by the composite model. If there is a significant deviation, this may indicate an abnormal operation.

Abstract: Methods and apparatus are provided for reducing torque ripple in a permanent magnet motor system comprising a permanent magnet motor coupled to an inverter. The method comprises the steps of receiving a torque command, generating a torque ripple reduction signal in response to the torque command, modifying operational control signals in response to the torque ripple reduction signal to generate reduced ripple operational control signals, and providing the reduced ripple operational control signals to the inverter for control of the permanent magnet motor.

Abstract: A process variable transmitter with diagnostics based on power spectral density (PSD) analysis of a process variable sensor signal is provided. In one embodiment, the process variable transmitter is a pressure transmitter and the diagnostics are used to diagnose impulse line obstruction or impending obstruction. Other diagnostics are also useful such as diagnosing primary element degradation. The sensor signal is digitized and the digitized signal is transferred into the frequency domain. The power of the frequencies on the sensor signal is examined to provide the enhanced diagnostics. In one aspect diagnostics are generated directly with the sensor PSD data. In another aspect, the PSD analysis is used to tune a filter in order to enhance traditional diagnostic algorithms.

Abstract: A system for detecting abnormal operation of at least a portion of a process plant includes a model to model at least the portion of the process plant. The model may be configurable to include multiple regression models corresponding to multiple different operating regions of the portion of the process plant. The system may also include a deviation detector configured to determine if the actual operation of the portion of the process plant deviates significantly from the operation predicted by the model. If there is a significant deviation, this may indicate an abnormal operation.

Abstract: A clutch reaction plate includes an annular device having a plurality of radially configured, alternating inwardly-oriented splines and keys, the splines and keys configured to meshingly engage a coaxial correspondingly-splined second device inserted therein. Selected ones of the splines include a bi-directional impact absorption device configured to engage selected ones of the splines of the inserted second device when a torque load is applied in one of a first rotational direction and a second, opposing rotational direction. The remaining splines engage the remaining splines of the inserted second device when the applied torque load exceeds a reaction force of the bi-directional impact absorption device.

Abstract: Methods and systems to detect steady-state operations in a process of a process plant include collecting process data. The collected process data is generated from a plurality of process variables of the process. A multivariate statistical model of the operation of the process is generated using the process data. The multivariate statistical model may be generated from a principal component analysis. The model is executed to generate outputs corresponding to the most significant variations in the process. Statistical measures of the outputs are generated and used to determine whether a steady-state or unsteady-state is related to the process.

Abstract: A system and method for detecting abnormal situations associated with a stirred vessel in a process plant receives statistical data associated with a pressure within a stirred vessel. A pressure signal associated with the pressure in the vessel is filtered by a digital filter to isolate a frequency component corresponding to pressure changes caused by the movement of a blade of an agitator through a fluid. For example, a pressure sensor device disposed at least partially within the stirred vessel may generate the statistical data based on a pressure signal. The statistical data is analyzed to detect whether one or more abnormal situations associated with an agitator of the stirred vessel exist. For example, the statistical data may be analyzed to detect whether the agitator is broken/unbalanced, corroded, missing a blade or multiple blades, etc. If an abnormal situation is detected, an indicator of the abnormal situation may be generated.

Abstract: Systems and methods for optimizing the process of segregating undesired mail using an incoming mail sorter are described and in certain examples, systems including those for using information feed-forward and/or feedback systems for making selective physical delivery decisions in the process of sorting and delivering incoming physical mail are described.

Abstract: Systems and methods for providing evidence of printing in metering systems even in the event of a print head failure are provided. Along with generating a primary image for an indicium that evidences payment, a secondary image for the indicium, identical to a corresponding portion of the primary image but at a lower density, with physical boundaries that are within the boundaries of the primary image, is also generated. The primary image is printed by a first nozzle array, and the secondary image is printed by a second nozzle array. Because the primary image completely overlaps the secondary image, the secondary image is undetectable if the primary image is properly printed. The secondary image provides evidence of printing of the indicium that can be used to obtain a refund for the indicium in the event that the primary image was not printed due to failure of the first nozzle array.

Abstract: A device and method for enhancing edge sharpness and clarity of solid graphic shapes included in printed color images printed on low dot-per-inch color printers is presented. The improved printing is achieved by creating an additional image file, called a white file, which defines the solid graphic areas to be included in the printed image. This white file is combined with the data points in separate color image files to “cookie-cut” the alphanumeric characters and other solid shapes from the separate color image files created by the ripping process, leaving crisp sharp edges on alphanumeric characters and other solid graphic areas being superimposed on the printed color image.

Abstract: The present invention includes apparatus and methods for handling mailpieces. A mailpiece handling device includes a substantially horizontal deck for receiving a mailpiece. The device also includes a substantially vertical registration wall that extends upwardly from an edge of the deck. The device further includes a disk mounted for rotation in a circular opening in the deck adjacent the registration wall. The disk has a substantially horizontal surface. In addition, the device includes an arm mounted above the disk so as to be pivotable in a horizontal direction. Also, the device includes a steering member mounted at a free end of the arm. The steering member is for applying downward pressure to a mailpiece that is in contact with the disk.

Abstract: A method for printing indicia on mailpieces at an increased average speed. The system includes: a postal scale for determining a postage amount for a mail piece; a printer; and a postage meter responsive to the postal scale to control the printer to print an indicium representative of the postage amount. The postage meter further includes: a programmable controller; a secure mechanism for accounting for postage amounts expended; and an indicia generator.

Abstract: A system for gathering data associated with a process plant, in which parameters are generated by a plurality of signal processing data collection blocks, automatically determines parameters to be monitored. The signal processing data collection blocks may generate data such as statistical data, frequency analysis data, auto regression data, wavelets data, etc. Then, the system monitors the determined parameters.

Abstract: In methods and systems that may facilitate detecting abnormal operation in a process plant, values of a process variable are analyzed to determine whether they significantly deviate from expected values. If there is a significant deviation, an indicator may be generated. Analyzing the process variable may include, for example, determining whether a number of values of the process variable are increasingly deviating from expected values, or determining whether the process variable is cycling. Analyzing the process variable may also include, for example, processing and analyzing the process variable to determine whether the process is in a normal state, one or more abnormal states, or an indeterminate state.

Abstract: A reduced rule set for identifying a root cause of an aberration in an industrial process is generated from a complete rule base. The rule base includes plurality of rules for the industrial process, and each rule comprises a condition of at least one process signal of the industrial process and a fault which corresponds to the condition of at least one process signal. Available process signals are identified. Rules are selectively removed from the rule base to produce the reduced rule set.

Abstract: Methods and apparatus are provided for reducing torque ripple in a permanent magnet motor system comprising a permanent magnet motor coupled to an inverter. The method comprises the steps of receiving a torque command, generating a torque ripple reduction signal in response to the torque command, modifying operational control signals in response to the torque ripple reduction signal to generate reduced ripple operational control signals, and providing the reduced ripple operational control signals to the inverter for control of the permanent magnet motor.

Abstract: In a mailing machine, an image element included in a postage meter indicium printed on a mail piece is transported past a linear image capture device. The image capture device is operated to produce a smeared image of the image element. The smeared image is then automatically analyzed to detect failures in the print elements of a postage meter that is part of the mailing machine.

Abstract: Systems and methods are provided for detecting abnormal conditions and preventing abnormal situations from occurring in controlled processes. Statistical signatures of a monitored variable are modeled as a function of the statistical signatures of a load variable. The statistical signatures of the monitored variable may be modeled according to an extensible regression model or a simplified load following algorithm. The systems and methods may be advantageously applied to detect plugged impulse lines in a differential pressure flow measuring device.

Abstract: An image of a moving object, such as a postage indicium barcode on a mail piece, is captured with the object in motion (e.g., while being transported through a mailing machine). An array of CMOS picture elements is held in a reset condition. A signal asserted on control pin ends the reset condition and places the picture elements in an image capture condition. With the picture elements in a picture capture condition, a strobe light is actuated at a time when the barcode is predicted to be present at the picture element array. After the strobe light has been actuated, the signal on the control pin is de-asserted to initiate a read-out of the image data from the picture elements.

Abstract: A system for preventing abnormal situations in process plants is provided. A polynomial regression model is employed to predict values of a monitored variable based on measured samples of a load variable. An abnormal situation is detected when a predicted value of the monitored variable differs from a measured value of the monitored variable by more than a predetermined. The system recognizes when a data model is invalid and takes steps to compensate for the invalid model.