Blockchain PLC Data Logging for Real-Time Defect Traceability
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Solution Overview
Problem
In industrial sites, managing and supervising the vast and diverse processes of vehicle production is challenging due to the difficulty in detecting defective parts and assembly defects, leading to quality deterioration and customer complaints, as existing methods are inefficient in real-time monitoring and data management.
Innovation Solution
A blockchain generation system that detects condition statement data from programmable logic controller (PLC) memories and stores it in a blockchain network, allowing real-time monitoring and sharing of data across client servers to prevent forgery and falsification, thereby improving quality and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional data management methods are used to monitor process equipment, then device complexity is reduced, but measurement precision and reliability of data detection deteriorate
Solution Approach 1:
The patent introduces a blockchain network as an intermediary layer between the PLC memory and the monitoring system. The data detector periodically queries PLC memory through the blockchain network, which acts as a mediator to securely transmit and verify data without requiring direct complex connections between all system components. This intermediary structure enhances detection precision while managing system complexity through standardized communication protocols.
Solution Approach 2:
The system creates copies of data from PLC memory and stores them in the blockchain network. The data detector periodically queries these copied data from the blockchain rather than directly accessing PLC memory every time, which improves detection precision through verified data copies while reducing the complexity of direct real-time memory access mechanisms.
2Productivity
If individual process monitoring is implemented manually, then manufacturing precision is maintained, but productivity and time efficiency deteriorate
Solution Approach 1:
The data detector is configured to periodically and automatically query data from PLC memory through the blockchain network without manual intervention. This continuous automated monitoring eliminates downtime between inspections and ensures uninterrupted data collection, significantly improving productivity while reducing the time loss associated with manual quality inspection processes.
Solution Approach 2:
The system implements automated feedback loops where the data detector continuously queries PLC memory, receives data through the blockchain network, and can trigger alerts or notifications when anomalies are detected. This automated feedback mechanism eliminates the need for manual monitoring cycles, improving productivity while reducing inspection time through immediate detection and response capabilities.
3Reliability
If data is stored in traditional databases, then ease of operation is maintained, but reliability and data integrity deteriorate due to potential forgery
Solution Approach 1:
The patent extracts the data storage and verification function from traditional centralized databases and implements it through the blockchain network. Data from PLC memory is copied and stored in the distributed blockchain ledger, which provides inherent data integrity and anti-forgery capabilities. This extraction of the storage function to a more reliable system improves data reliability while the blockchain's standardized structure helps manage the complexity of data verification.
Data Source
AI summary
A blockchain generation system included in each of servers forming a blockchain network includes a blockchain condition setting device that sets a blockchain configuration condition statement based on an operator's input to a screen of a user interface. A data detector detects result data stored in a memory of a programmable logic controller according to an operation of a process equipment based on the blockchain configuration condition statement. A blockchain generator generates blockchain data based on the result data detected from the memory of the programmable logic controller and transmits the blockchain data to a plurality of client servers connected via the blockchain network. A storage device stores the blockchain data and store blockchain data received from the client servers.