Control Logic for Time-Aligned Abnormality Detection
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Solution Overview
Problem
Existing control apparatuses in Factory Automation (FA) technology, such as PLCs, struggle to effectively monitor and detect abnormalities using measurement values from different measurement points or processes, as they do not provide a solution for timing adjustments needed to account for time lags between events in measurement values.
Innovation Solution
A control apparatus with an acquisition unit, a determination unit, and a delay time adding unit that acquires and adjusts measurement values by adding a predetermined delay time based on the difference between mechanisms or processes, using design data or actual measurement values, and employing a buffer memory to optimize data access and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If measurement values from different measurement points or processes are used for abnormality detection, then the monitoring coverage and detection capability are improved, but time lags between events in different measurement values cause determination errors
Solution Approach 1:
The patent applies preliminary action by calculating and storing delay time information in advance based on design data before actual operation. This pre-calculated delay time is then used to correct measurement values in real-time, allowing the system to compensate for time lags without adding computational overhead during critical detection moments.
Solution Approach 2:
The patent changes the time parameter of measurement values by applying delay time corrections. Different measurement values are adjusted by different delay amounts based on their respective delay time information, synchronizing them to a common reference time and enabling accurate combined analysis.
2Measurement precision
If delay time correction is applied to synchronize measurement values, then determination accuracy is improved, but system complexity increases due to additional processing requirements
Solution Approach 1:
The patent reduces runtime complexity by performing delay time calculations in advance using design data. The pre-calculated delay time information is stored and directly applied during operation, avoiding complex real-time calculations and simplifying the control apparatus requirements.
Solution Approach 2:
The system uses its own design data and operational parameters to automatically calculate and determine the delay time information without requiring external calibration or manual intervention. This self-determination capability simplifies the overall system architecture.
3Adaptability or versatility
If delay time is determined based on actual measurement values rather than design data, then adaptability to real-world conditions is improved, but the ability to predict and prepare delay time information is reduced
Solution Approach 1:
The patent implements feedback by using actual measurement values and their temporal relationships to calculate delay time information. This feedback mechanism allows the system to adapt to real-world operational conditions while maintaining the ability to predict future behavior based on learned patterns.
Solution Approach 2:
The patent determines delay time based on actual operational parameters and measurement value relationships, allowing the system to adapt to real-world variations in process conditions, equipment behavior, and environmental factors that differ from idealized design data.
Data Source
AI summary
A control apparatus for controlling a control target includes: an acquisition unit, a determination unit, and a delay time adding unit. The acquisition unit acquires at least first and second measurement values related to a control target, such as a machine. The determination unit determines whether the control target is in a predetermined state, such as a normal state or an abnormal state, based on the measurement values acquired by the acquisition unit. The delay time adding unit adds delay to at least one of the first and second measurement values.