FA Control Program Trial Workflow Using Time-Chart Feedback
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Solution Overview
Problem
In factory automation (FA), the development period of control programs for controlling multiple devices is prolonged due to repeated exchanges between control designers and on-site workers, as on-site workers lack programming skills and control designers lack site-specific knowledge, leading to inefficiencies in program updates and modifications.
Innovation Solution
A trial management system that includes a virtual execution unit, step execution unit, presentation unit, reception unit, and update unit, allowing on-site workers to provide intuitive feedback through time charts, which are used to update evaluation criteria, thereby reducing the need for redesign and shortening the development period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If control designers directly modify control programs based on on-site worker reports, then program accuracy can be improved, but development period increases due to repeated exchanges
Solution Approach 1:
The patent introduces a trial management system as an intermediary between on-site workers and control designers. The system automatically acquires trial results from control devices, generates time charts, and presents them to workers for evaluation. This mediator eliminates the need for repeated direct communication, as the system autonomously processes and translates operational feedback into actionable program corrections.
Solution Approach 2:
The trial management system enables self-service by automatically collecting trial data from control devices during actual operations, generating visual time charts, and presenting evaluation results without requiring control designers' direct involvement. The system serves itself by autonomously managing the feedback loop between field operations and program refinement.
2Productivity
If on-site workers modify control programs directly, then update speed can be improved, but program reliability decreases due to lack of programming skills
Solution Approach 1:
The trial management system acts as an intermediary that bridges on-site workers and control programs. Workers evaluate visual time charts and provide feedback through the system, which then automatically translates this feedback into program modifications. This intermediary approach enables workers to participate in program updates without needing programming expertise, maintaining reliability while improving update speed.
Solution Approach 2:
The patent replaces the mechanical system of direct program editing with an automated information processing system. Instead of workers manually coding or modifying programs, the system uses automated data acquisition, visual presentation, and algorithmic translation of feedback into program corrections, substituting human programming skills with automated intelligence.
3Manufacturing precision
If control designers are familiar with site know-how, then program appropriateness can be improved, but adaptation to site conditions becomes difficult
Solution Approach 1:
The trial management system provides universal functionality by serving multiple purposes: it collects trial data, generates visual time charts, presents information to workers, receives evaluations, and automatically updates control programs. This multi-functional system adapts to different site conditions and program types without requiring designers to learn specific site know-how, as the system itself handles the adaptation through automated processing.
Data Source
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AI summary
Provided is a control program trial management system for shortening a development period of a control program for comprehensively controlling a plurality of control devices in FA. A trial management system according to the present disclosure includes: a virtual execution unit configured to cause a simulation program to virtually execute a control program created by a control designer; a step execution unit configured to execute the control program for an individual step preset to cause a control device to actually operate when an execution result of the virtual execution unit satisfies a criterion preset; a presentation unit configured to generate a time chart representing an operation progress in the individual step and present the time chart to an on-site worker; a reception unit configured to receive an evaluation of the time chart by the on-site worker; and an update unit configured to update, based on the evaluation accepted by the reception unit, the criterion.