Automation Fault Diagnosis Using Triggered Feedback Capture
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Solution Overview
Problem
Modern manufacturing and automation systems face challenges in diagnosing complex and intermittent faults due to their complexity and speed, making it difficult to identify the cause of defects or machine stoppages, especially in systems that require minimal disruption and are heavily regulated.
Innovation Solution
A method and system for diagnosing automation systems that includes a server module independent of the automation controller, which triggers data collection devices to gather feedback data around trigger conditions, allowing for continuous data collection and storage without reconfiguring existing systems, and enables configurable settings for pre- and post-event capture times, facilitating efficient fault identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera is connected with PLC and PLC is re-programmed to provide trigger signal, then diagnostic capability is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent introduces an independent server module as an intermediary between the camera and the PLC. This server module receives machine data from the PLC and independently determines trigger conditions and collects video data, eliminating the need to reprogram the PLC or add complex trigger hardware connections.
Solution Approach 2:
The diagnostic system is segmented into independent functional modules: the existing PLC continues its primary control function, while a separate server module handles diagnostic data collection and analysis. This segmentation allows the diagnostic system to be added without modifying the core control system.
2Measurement precision
If diagnostic system is integrated with automation controller, then diagnostic accuracy is improved, but ease of operation and adaptability deteriorate
Solution Approach 1:
The server module acts as an independent intermediary that interfaces with the existing PLC through standard communication protocols. It receives machine data, independently processes it to determine trigger conditions, and collects diagnostic data without requiring integration into the automation controller's internal architecture.
Solution Approach 2:
The server module is designed as a universal diagnostic platform that can be applied to various existing automation systems without customization. It handles multiple data sources and trigger conditions through software configuration rather than hardware integration, making it adaptable to different manufacturing environments.
3Reliability
If extensive system reconfiguration is performed for diagnostic setup, then diagnostic reliability is improved, but productivity and loss of time deteriorate
Solution Approach 1:
The server module is pre-configured with diagnostic algorithms and trigger condition logic before deployment. It automatically receives machine data from the PLC and is ready to independently determine trigger conditions and collect video data immediately, eliminating the need for time-consuming on-site system reconfiguration or PLC reprogramming.
Data Source
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AI summary
The disclosure is directed at a method and system for diagnosing automation elements. The method and system include the determination of a trigger condition or event within operation data received from the automation elements. Based on the trigger condition or event, feed-back data captured by data collection devices is tagged and stored and/or captured and stored for review by an end user. The feed-back data may be stored together with associated operation data to assist in identifying faults, the causes of faults, or the like in the automation elements, in the products produced, or in the manufacturing process or overall manufacturing system.