Dynamic Operator Interface for Industrial Automation

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Solution Overview

Problem

Current Programmable Logic Controller (PLC) architectures are inflexible and require reprogramming to adapt to changing manufacturing dynamics, such as changes in raw materials inventory or process conditions, which is time-consuming and costly, and do not effectively integrate with higher-level business workflows.

Innovation Solution

Implementing a dynamic operator interface system that uses a business execution language to communicate changes bidirectionally between higher-level business processes and lower-level control operations, allowing for automatic adaptation without reprogramming the PLC, enabling operators to interact with changing conditions and adjust processes dynamically.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If PLC is reprogrammed to adapt to changing manufacturing dynamics, then adaptability improves, but time consumption and cost increase

Engineering Contradiction:

Improveadaptability to manufacturing changesVSAvoidtime for reprogramming

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The operator interface is made dynamically reconfigurable through a transaction engine that processes business transactions and automatically modifies interface parameters, control parameters, and routing parameters in real-time based on changing manufacturing conditions, eliminating the need for reprogramming

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A transaction engine is introduced as an intermediary component that sits between the operator interface and the PLC, translating business transactions into appropriate control actions and interface modifications, thereby decoupling the need for interface changes from PLC reprogramming

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If PLC is reprogrammed to account for process changes, then process control accuracy improves, but manufacturing cost increases

Engineering Contradiction:

Improveprocess control accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The operator interface system performs self-adjustment through automated transaction processing, where the transaction engine automatically modifies interface and control parameters based on incoming business transactions, eliminating the need for manual engineering intervention and associated costs

Inventive Principle:

Principle #25Self-service

3Reliability

If PLC operations are standardized, then system reliability improves, but flexibility to account for changing conditions worsens

Engineering Contradiction:

Improvesystem reliabilityVSAvoidflexibility to changing conditions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system maintains standardized PLC operations while introducing dynamic adaptability through the transaction engine, which processes business transactions and automatically adjusts interface parameters, control parameters, and routing parameters without modifying the underlying standardized PLC logic

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The transaction engine serves as an intermediary layer that handles adaptability requirements, allowing the standardized PLC to maintain reliability while the intermediary dynamically adjusts parameters and routing based on changing business conditions

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If bidirectional communication is implemented between business processes and control operations, then operational efficiency improves, but system complexity increases

Engineering Contradiction:

Improveoperational efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The transaction engine performs multiple functions including processing business transactions, modifying operator interface parameters, adjusting PLC control parameters, and routing transactions to appropriate destinations, thereby managing system complexity through a multi-functional component rather than multiple separate systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8204609B2Industrial operator interfaces interacting with higher-level business workflow

Publication Date: 2012.06.19 ROCKWELL AUTOMATION TECH INC

AI summary

Systems and methods are provided that enable high-level and abstract business engines to affect and influence plant-floor or industrial operations via dynamic and flexible operator interfaces. In a similar manner, actions directed from the operator interfaces can be communicated to higher level decision components of an enterprise to facilitate automated control and dynamics of the enterprise. In one aspect, an industrial automation system is provided. The system includes one or more controllers to process transaction events in an industrial automation environment. One or more operator interface components are provided that automatically adapt interface control functionality based on the transaction events.