Automation Interface for Cross-Machine Data Consolidation
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Solution Overview
Problem
In industrial facilities with multiple machines and controllers, consolidating process data from independent machines is challenging, leading to missed opportunities for improving efficiency and reducing downtime due to the lack of integrated analysis of interactions between machines and systems.
Innovation Solution
An automated operating system (AOS) that accumulates data from various elements and machines across an enterprise, analyzes it using a server to identify issues and trends not visible to individual machine controllers, and generates real-time data displays for monitoring and managing operations, enabling proactive responses to prevent issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If independent machine controllers are used to control each machine, then each machine can be operated independently, but consolidation of process data from multiple machines becomes difficult and interactions between machines cannot be analyzed
Solution Approach 1:
The patent introduces a server as an intermediary component that receives process data from multiple independent machine controllers and a facility controller. This server consolidates and analyzes the data to identify interactions between machines, zones, and production lines, enabling centralized monitoring without compromising the independence of individual machine operations.
2Device complexity
If process data from multiple machines is not consolidated for analysis, then system complexity is reduced, but opportunities to increase facility efficiency and decrease facility downtime are missed
Solution Approach 1:
The server is designed with multi-functionality to perform various data consolidation and analysis tasks. It receives data from multiple sources (machine controllers and facility controller), consolidates process data from different machines and zones, analyzes interactions between production elements, and generates comprehensive reports. This universal approach enables facility-wide efficiency improvements without requiring separate specialized systems for each function.
3Ease of operation
If manual tools are used in controlled processes, then operational flexibility is maintained, but consolidation of process data becomes difficult
Solution Approach 1:
The system implements feedback mechanisms where manual tools equipped with sensors provide real-time process data back to the server. This feedback loop enables the consolidation of data from manual operations, allowing the centralized system to monitor and analyze processes involving manual tools just as effectively as automated processes, thereby maintaining operational flexibility while achieving data consolidation.
Data Source
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AI summary
A system and method for controlling automation includes a machine performing at least one operation and including a sensor for generating data in response to a performance of the operation by the machine. Data generated by the sensor is stored for retrieval by a server in data memory storage. The server includes at least one display template for displaying the data, and the server generates a data display by populating the at least one display template with the data. The data template can be populated with data in real time, to display the data display immediate to the generation of the data. The display template includes a data feature which is differentiated for displaying the data feature in a mode determined by the data populating the data display. The data display can be displayed in real time by a user device in communication with the server.