Industrial Controller Skill Matching for Machine Replacement Compatibility
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Solution Overview
Problem
Manual matching of interface and process information between industrial production machines and controllers is time-consuming and often results in downtime due to hidden parameter and skill incompatibilities during refit, replacement, or upgrade processes.
Innovation Solution
Automated skill matching using augmented unification and synchronous cross product of finite state automata to detect and resolve incompatibilities between machine and controller interfaces and processes, reducing the need for manual engineering and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual matching of interface and process information is performed, then compatibility between machine and controller can be verified, but time consumption and engineering hours increase significantly
Solution Approach 1:
The patent replaces manual mechanical matching processes with automated computer-based processing. The control device automatically compares interface information and process information between machine and controller using electronic data processing, eliminating the need for manual engineering hours while maintaining compatibility verification reliability.
Solution Approach 2:
The control device performs self-verification by automatically comparing its own interface and process information with the machine's information. This self-service capability allows the system to identify incompatibilities without external manual intervention, reducing time consumption while ensuring reliable compatibility checking.
2Reliability
If manual matching is performed to ensure interface and process compatibility, then incompatibilities can be detected, but production downtime increases during refit or replacement
Solution Approach 1:
The control device performs compatibility verification in advance before production operations begin. By automatically comparing interface and process information beforehand, the system detects potential incompatibilities during planning rather than during execution, minimizing production downtime during refit or replacement operations.
Solution Approach 2:
The patent replaces time-consuming manual matching with automated electronic comparison processes that can verify compatibility rapidly. This substitution reduces the time required for incompatibility detection from hours or days of manual work to much faster automated processing, minimizing production downtime.
3Reliability
If manual engineering is used to match interfaces and processes, then compatibility can be achieved, but the complexity and skill requirements increase
Solution Approach 1:
The control device automatically performs the complex task of comparing interface information and process information between machine and controller. This self-service capability handles the complexity of matching parameters, data types, and processes without requiring external engineers, thereby reducing skill requirements while maintaining matching reliability.
Solution Approach 2:
The patent replaces complex manual engineering processes with automated computer-based comparison algorithms. The electronic processing system handles the intricate task of matching interfaces and processes, reducing the perceived complexity for operators while ensuring reliable compatibility through systematic automated verification.
4Productivity
If automated skill matching is implemented, then time required for machine replacement decreases, but system complexity increases
Solution Approach 1:
The control device performs multiple functions including controlling the machine, storing interface information, storing process information, and automatically comparing compatibility. This multi-functionality consolidates the automated matching system within the existing control device, reducing overall system complexity while maintaining high productivity during machine replacement.
Solution Approach 2:
The patent merges the automated skill matching functionality with the existing control device rather than adding separate dedicated hardware. By combining interface information storage, process information storage, and comparison functions within the control device itself, the system achieves fast machine replacement without proportionally increasing system complexity.
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
Automated skill matching is provided in industrial control. The interfaces (12, 17) and/or the production processes (13, 18) of the controller (16) and machine (11) are matched. The matching of the interfaces (12, 17) links parameters except for optional parameters to check for incompatibility. The matching of the production processes (13, 18) uses a cross-product of the process (13) of the machine (11) with the process (18) of the controller (16) to check for incompatibility. The skill checking guides manual confirmation of compatibility, reducing downtime and reducing engineering or programming time. The machine (11) is more likely to operate correctly with the controller (16) due to the automated skill matching.