Control Program Management System with Approval Workflow
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Solution Overview
Problem
Existing methods for changing control parameters or logic in power generation plants do not effectively prevent content errors and do not meet the safety standards set by IEC 61508 and JIS C 0508, potentially leading to misoperations.
Innovation Solution
A control program management system that involves an editing device for generating new control programs, an approval-receiving device for confirming and approving the content of these programs, and a control arithmetic device that only implements the changes after receiving approval from a third-party manager, utilizing CRC codes for error detection and ensuring proper user authorities are followed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators or maintenance engineers directly change control parameters or logic during operation, then the ease of operation is improved, but the reliability deteriorates due to potential misoperations and content errors
Solution Approach 1:
The patent introduces an approval-receiving device as an intermediary between the editing device and control arithmetic device. This mediator verifies the authority of operators, checks for content errors in proposed changes, and requires approval before implementing modifications. This resolves the contradiction by enabling easy operation through direct interface while maintaining reliability through intermediate verification steps.
Solution Approach 2:
The patent implements preliminary verification actions before control program changes are executed. The system checks operator authority, detects content errors in the new control program, and requires approval from designated personnel before applying changes. This preliminary action ensures reliability is maintained while allowing ease of operation during the actual change process.
2Reliability
If version checking and authority checking methods are implemented, then the reliability is improved, but they do not prevent content errors in control programs
Solution Approach 1:
The patent replaces manual verification methods with automated error detection mechanisms. The approval-receiving device automatically checks the new control program for content errors using error detection codes (such as CRC codes) before approval is given. This substitution of automated detection for manual checking improves both reliability and content accuracy simultaneously.
Solution Approach 2:
The approval-receiving device serves as an intermediary that performs both authority verification and content error detection. It receives the new control program, verifies operator authority, checks for content errors using error detection codes, and only allows implementation if both checks pass. This intermediary function simultaneously addresses both reliability and manufacturing precision concerns.
3Reliability
If third-party approval process is implemented, then the reliability is improved by preventing content errors, but the productivity deteriorates due to additional approval steps
Solution Approach 1:
The system implements self-service error detection using automated error detection codes (such as CRC codes) that are calculated and verified by the approval-receiving device itself. This automated self-verification reduces the burden on third-party approvers, allowing them to quickly validate error detection codes without manually reviewing entire control programs, thus maintaining reliability while improving productivity.
Solution Approach 2:
The patent replaces manual content review with automated error detection code verification. The approval-receiving device automatically calculates and verifies error detection codes of the new control program, substituting time-consuming manual content inspection with rapid automated verification. This maintains reliability through thorough error checking while significantly improving the speed of the approval process.
Data Source
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AI summary
A control calculation device causes the contents of a new control program received from an editing device to be displayed on an approval-receiving device. The approval-receiving device receives an input from a manager comprising approval information expressing whether or not a change to the control program is approved. The control-calculation device changes the control program to the new control program when the approval information received from the approval-receiving device is information indicating approval of the new control program.