Aggregation Server for Industrial HMI Data Management
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Solution Overview
Problem
In industrial automation environments, frequent data requests from multiple communication devices put strain on Human-Machine Interfaces (HMIs), machines, and network resources, leading to inefficiencies and potential overload.
Innovation Solution
An aggregation server is introduced to service requests for operation and graphics data, reducing the demand on HMIs and machines by storing and managing data transfers, and limiting simultaneous requests to prevent overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple communication devices frequently request data directly from HMIs and machines, then data access responsiveness is improved, but system load and network strain increase
Solution Approach 1:
An aggregation server is introduced as an intermediary component between communication devices and HMIs/machines. The aggregation server receives data requests from multiple communication devices, consolidates them, and retrieves data from HMIs or machines in optimized batches. This mediator architecture maintains fast data access for remote users while preventing overload on critical system components through intelligent request management and load distribution.
2Adaptability or versatility
If HMIs service multiple remote communication devices simultaneously, then remote accessibility is improved, but HMI processing capacity is exceeded
Solution Approach 1:
The system architecture is segmented into distinct functional layers: communication devices for user access, an aggregation server for request management and data consolidation, and HMIs/machines for data generation. This segmentation allows multiple communication devices to access remote data simultaneously through the aggregation server's load management capabilities, while HMIs only process essential data generation tasks, preventing processing capacity exhaustion.
3Loss of information
If frequent data requests are transmitted over the network, then data freshness is improved, but network bandwidth consumption increases
Solution Approach 1:
The aggregation server merges multiple individual data requests from different communication devices into consolidated batch requests to HMIs and machines. Instead of each device independently polling for data, the server aggregates timing and content requirements, retrieves data in optimized batches, and redistributes to waiting devices. This maintaining data freshness for all users while dramatically reducing total network traffic and bandwidth consumption.
Data Source
AI summary
A human-machine-interface (HMI) system comprises a machine interface, a communication interface, and a processing system. The machine interface receives operation data from a plurality of machines within an industrial automation environment, wherein the operation data corresponds to operations of the plurality of machines. The communication interface receives a request for a remote viewing session from a communication device, and in response to the request, transfers graphics data and the operation data for delivery to and display by the communication device. The processing system monitors for changes to the graphics data and the operation data during the remote viewing session. The communication, upon a change occurring to the graphics data, transfers updated graphics data for delivery to and display by the communication device, and upon a change occurring to the operation data, transfers updated operation data for delivery to and display by the communication device.