Industrial Device Assembly Auto-Commissioning for Faster Startup
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Solution Overview
Problem
The manual programming and configuration of industrial device assemblies, such as motor control centers and switchgear, are time-consuming and prone to errors, leading to delays in project completion.
Innovation Solution
An automatic commissioning system that generates data files containing specification and control blocks for industrial automation devices, allowing for pre-programming of controllers before the devices arrive at the site, thereby minimizing manual intervention and reducing setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual programming and configuration is used for industrial device assemblies, then flexibility and adaptability are maintained, but commissioning time increases significantly and errors occur
Solution Approach 1:
The system performs preliminary programming and configuration actions during the manufacturing phase, generating control code and configuring device parameters before the industrial device assembly is shipped to the customer site. This advance preparation eliminates the need for time-consuming manual commissioning at the installation site.
Solution Approach 2:
The system uses specification data from customer orders to automatically generate control code and configuration data, creating a digital copy of the required system behavior that is then transferred to the control system, replacing manual programming with automated code generation.
2Adaptability or versatility
If manual programming is performed at the industrial site, then customization is possible, but project completion delays occur
Solution Approach 1:
The control system performs self-configuration and self-programming by automatically reading specification data and generating the necessary control code without requiring manual intervention from technicians at the installation site, thereby maintaining adaptability while accelerating deployment.
Solution Approach 2:
All customization and configuration work is performed in advance during manufacturing based on customer specifications, so that when the device arrives at the site, it is already customized and ready for immediate operation, eliminating on-site programming delays.
3Loss of time
If automatic commissioning is implemented, then commissioning time is reduced, but system complexity increases
Solution Approach 1:
The system introduces a commissioning server as an intermediary that receives customer specifications, generates control code, and transfers it to the control system. This intermediary automates the complex processes of code generation and configuration, reducing commissioning time while managing system complexity through a dedicated automated component.
Solution Approach 2:
The system replaces manual mechanical programming processes with automated electronic code generation and digital configuration, using software-based solutions to perform tasks that previously required manual technician intervention, thereby reducing commissioning time while the complexity is managed through automation.
Data Source
AI summary
A system has a processor that may receive an order of an industrial device assembly having multiple industrial automation devices. The processor may also generate a first data file based on the order of the industrial device assembly. The first data file may have specification data associated with each industrial automation device and hierarchical information associated with each industrial automation device. Additionally, the processor may generate a second data file based on the first data file. The second data file has one or more control blocks of code associated with each industrial automation device. Further, the processor may transmit the second data file to a control system associated with the industrial device assembly. The control system is automatically programmed based on the second data file to control one or more operations of each industrial automation device in the industrial device assembly.