Automation Control Program Updates for Error Analysis
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Solution Overview
Problem
Complex industrial automation systems face challenges in error analysis and handling due to unknown future error events and reactions, leading to insufficient error data collection and inadequate error handling, requiring laborious manual or semi-automated procedures.
Innovation Solution
A method for operating automation components using a control program that detects error events, downloads and updates control program components from a central system based on error events and process images, enabling automatic error analysis and correction, and selecting suitable control program components based on device identifiers or types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If error handling is programmed before automation component delivery, then error handling procedures are prepared in advance, but error data collection is insufficient because future error events are unknown
Solution Approach 1:
The control program is made dynamically updateable by downloading additional control program components from a central system based on detected error events. This allows the error handling capability to evolve from a static pre-programmed state to a dynamic state that adapts to actual error events encountered during operation, thereby improving both error handling and error data collection simultaneously.
Solution Approach 2:
A lean control program with basic error handling procedures is installed during initial setup, preparing the automation component for operation. Subsequently, additional control program components are downloaded and installed based on actual error events, combining preliminary preparation with adaptive supplementation to resolve the contradiction between advance preparation and comprehensive error data collection.
2Reliability
If comprehensive error handling is implemented, then error analysis capability is improved, but device complexity increases requiring complex semi-automated analysis
Solution Approach 1:
The control program is segmented into a lean base program installed during setup and additional modular control program components that are downloaded and installed as needed based on specific error events. This segmentation allows comprehensive error handling capability to be built incrementally without initially complex device architecture, reducing the need for complex semi-automated analysis.
3Adaptability or versatility
If error handling is installed retrospectively, then error handling for new error events is improved, but installation process becomes complex and time-consuming
Solution Approach 1:
The automation component is equipped with the capability to automatically download and install additional control program components from a central system based on detected error events. This self-service mechanism eliminates the need for complex manual or retrospective installation processes, allowing the system to automatically adapt its error handling capability while simplifying the installation process.
Solution Approach 2:
The system implements a feedback loop where error events detected during operation trigger automatic downloading and installation of relevant control program components from a central system. This feedback-driven approach enables retrospective error handling improvement while automating the installation process, thereby maintaining ease of manufacture while enhancing adaptability.
Data Source
Figure 1~2
AI summary
The invention relates to a method for operating an automation component by means of a control program having a plurality of control program components, the method comprising the steps: detecting (S101) error events of the control program during an operation of the automation component, downloading (S102) a current control program component for error analysis based on error events from a central system, and updating (S103) an existing control program component for error analysis by way of the current control program component for error analysis.