Factory Control System for Continuous Sensor Data During Manual Override
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Solution Overview
Problem
In factory management systems, the transition from automated to manual operation often interrupts production processes and data transmission, rendering sensor data useless during abnormal conditions in the Industry 4.0 era.
Innovation Solution
A factory management system and control system that integrates sensors, a server, and an artificial intelligence module, allowing continuous data reception and user command transmission while sending warning messages upon abnormal conditions, ensuring uninterrupted production and data flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the control system interrupts production processes when users log in for manual operation, then users can safely intervene to fix abnormalities, but data transmission stops and sensor data becomes useless
Solution Approach 1:
The control system dynamically switches between automated operation mode and manual operation mode based on user login status. When a user logs in, the system transitions to manual mode while maintaining data reception capabilities, allowing flexible adaptation between different operational states without complete interruption
Solution Approach 2:
The control system maintains continuous reception and processing of sensor data even during manual operation when a user is logged in. The data transmission pipeline remains active, ensuring that sensor data continues to provide value for reference and analysis throughout the entire operational cycle
2Adaptability or versatility
If the control system switches between automated and manual modes, then user control is enabled, but production process interruption occurs
Solution Approach 1:
The system implements dynamic mode switching between automated and manual operations through user login/logout events. The control system adapts its operational characteristics in real-time based on user presence, enabling versatile operation modes while maintaining production flow through continuous data processing
Solution Approach 2:
The control system performs multiple functions simultaneously: it receives and processes sensor data, manages user authentication, handles manual control commands, and maintains production monitoring all within a unified system architecture, allowing seamless transition between automated and manual modes
Data Source
AI summary
A factory management system and control system are provided. The factory management system includes: a machine; multiple sensors disposed corresponding to the machine and generates multiple first sensing data; a server; and a control system coupled to the machine and the server. The control system receives the first sensing data to generate multiple corresponding control commands in real time and transmits the control commands to the machine. The control system receives a user login message and receives multiple second sensing data and displays the second sensing data in a user login status. The control system receives a user control command and transmits a second control command corresponding to the user control command to the machine. When the control system determines that an abnormal condition occurs according to the second sensing data in the user login status, the control system sends a warning message.