AR Safety Zone Overlays for Remote Industrial Troubleshooting
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Solution Overview
Problem
Industrial automation systems face challenges in providing timely and efficient access to operational data and troubleshooting guidance, as users often need to physically be near HMIs or industrial controllers to view status data, leading to delays in maintenance and potential revenue loss.
Innovation Solution
A system that generates and delivers augmented reality (AR) or virtual reality (VR) presentations to wearable devices, allowing users to view 3D holographic representations of industrial facilities, receive real-time data, and interact with industrial devices remotely, with features like live video feeds and interactive workflows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If users physically approach HMIs or industrial controllers to view status data, then they can access operational data and troubleshooting guidance, but it causes delays in maintenance and potential revenue loss due to the need for physical presence
Solution Approach 1:
The patent creates virtual copies of industrial facilities, equipment, and control systems through 3D holographic representations. These digital twins replicate the physical infrastructure, allowing users to view status data, troubleshoot issues, and interact with control systems remotely without physically approaching the actual equipment. This copying approach eliminates maintenance delays while preserving full access to operational data.
Solution Approach 2:
The patent introduces an augmented reality interface and wireless communication system as intermediaries between users and industrial control systems. This intermediary layer transmits operational data, status information, and control commands wirelessly to wearable devices, enabling remote access without physical presence near HMIs or controllers, thus eliminating delays while maintaining ease of operation.
2Productivity
If users are required to be near industrial equipment for troubleshooting, then they can directly observe and interact with the equipment, but it increases downtime and reduces productivity
Solution Approach 1:
The patent creates accurate virtual replicas of industrial equipment that replicate all visual, operational, and diagnostic characteristics. These 3D holographic models allow users to remotely observe equipment status, monitor operational parameters, and detect issues without physically approaching the machinery. The virtual copies maintain full fidelity for troubleshooting while enabling productivity improvement through reduced downtime.
Solution Approach 2:
The patent transitions equipment monitoring from physical space to augmented reality and virtual space. By projecting 3D holographic representations and overlaying diagnostic data in the augmented reality domain, users can detect and measure equipment status from remote locations. This dimensional shift eliminates the requirement for physical proximity while maintaining comprehensive monitoring capabilities.
3Adaptability or versatility
If traditional HMI systems are used for monitoring industrial facilities, then operational data can be displayed, but users must physically be near the HMI location which limits remote access capability
Solution Approach 1:
The patent creates virtual copies of HMI interfaces and control systems that can be accessed through wearable augmented reality devices. These digital replicas of control interfaces allow users to view operational data, monitor facility status, and interact with control systems from any location with wireless connectivity. The copied interface maintains full functionality while providing universal remote access capability.
Solution Approach 2:
The patent replaces the mechanical requirement of physical presence near HMI locations with wireless electronic communication and augmented reality display technology. Operational data is transmitted electronically to wearable devices, and control interactions are performed through the augmented reality interface. This substitution eliminates the mechanical constraint of physical proximity while maintaining ease of data viewing and system interaction from remote locations.
Data Source
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AI summary
An industrial visualization system generates and delivers virtual reality (VR) and augmented reality (AR) presentations of industrial facilities to wearable appliances to facilitate remote or enhanced interaction with automation systems within the facility. The presentation system can also leverage safety zone definition data to visualize graphical representations of defined safety zones within a line of sight of the wearable appliance. The safety zones can be rendered as three-dimensional semi-transparent overlays corresponding to the defined dimensions and location of the safety zone relative to its corresponding safety sensor. By visualizing defined safety zones as overlays within a wearer's field of view as part of an AR presentation, the presentation system can serve as a visual guide that helps the wearer to avoid inadvertently entering the safety zones, thereby reducing machine downtime due to accidental initiation of safety actions.