Automation HMI Emulation for Flexible Multi-Machine Control
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Solution Overview
Problem
Current automation systems, particularly cyber-physical production systems (CPPS), face challenges in flexible 'lot size 1' production due to the high costs of rewiring and software updates, limited flexibility in adapting to new production processes, and the need for precise measurement and adjustment of assembly stations, which increases costs and reduces efficiency in small batch production.
Innovation Solution
A method and computational device that allow for the control of automation systems by emulating user interactions with proprietary human-machine interfaces (HMIs) of diverse production machines, enabling flexible programming and coordination of machines without hardcoding or hardwiring, using graphical processing and machine learning algorithms to monitor and manipulate graphical elements in the HMIs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hard-wired production machines are used with proprietary control computers and HMIs, then machine control and coordination are achieved, but flexibility for lot size 1 production is lost due to expensive rewiring and recoding requirements
Solution Approach 1:
The patent replaces physical rewiring and manual recoding with a software-based emulation system. The computational device emulates user interactions with proprietary HMIs through graphical processing and machine learning algorithms, allowing production machines to be reconfigured for lot size 1 production without physical hardware changes or expensive manual programming.
Solution Approach 2:
The patent creates virtual copies of user interactions with the proprietary HMI interface. The computational device monitors graphical elements in the HMI and emulates user inputs by generating corresponding control signals, effectively copying the behavior of a human operator without requiring actual human intervention or physical reconfiguration of the machines.
2Adaptability or versatility
If frequent software updates are performed on production machines, then adaptability to new production processes is improved, but safety and reliability risks increase
Solution Approach 1:
The patent introduces a computational device as an intermediary layer between the control system and the production machines. This intermediary emulates user interactions with the HMIs and coordinates machine operations through virtual inputs, allowing software updates and process changes to be implemented safely without directly modifying the proprietary control systems of the production machines.
Solution Approach 2:
The computational device creates virtual representations of user interactions and control signals. By copying and emulating the behavior of human operators through graphical processing and machine learning, the system can adapt to new production processes while maintaining the integrity and safety of the original machine control systems.
3Manufacturing precision
If precise measurement and adjustment of assembly stations are performed, then manufacturing precision is improved, but device complexity and costs increase
Solution Approach 1:
The patent replaces physical measurement and adjustment mechanisms with a software-based emulation system. The computational device uses graphical processing and machine learning algorithms to monitor and emulate user interactions with the HMI, eliminating the need for expensive 3D cameras, lasers, and other high-performance positioning sensors while maintaining coordination precision between production machines.
Data Source
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AI summary
Provided is a method and a computation device for controlling an automation system, the system comprising at least one of a plurality of machines, each of the plurality of machines including a proprietary control computer and a proprietary human-machine-interface, i.e. HMI, the method comprising the steps of: providing a first program being implemented on the proprietary control computer, the first program comprising at least an operating instruction for carrying out an operation by the at least one machine, and at least a displaying instruction for displaying a graphical element in the proprietary HMI; monitoring the graphical element of the proprietary HMI by a second program being implemented on a computation device, which is connected to the automation system; operating the first program by means of triggering a user input to the proprietary HMI, the user input being emulated by the second program based on the monitored graphical element.