Field Device Test Pattern Execution for Faster Loop Maintenance
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Solution Overview
Problem
In industrial plants, the efficiency of maintenance work for field devices is reduced due to the need for repeated setting of test output values for loop tests across multiple devices, especially when a large number of devices require similar test patterns, leading to increased workload and reduced productivity.
Innovation Solution
A device maintenance apparatus with a touch panel interface that allows for the automatic detection of field devices, storage of device information, and determination of relevant maintenance items, enabling one-touch execution of maintenance tasks and reducing the need for repetitive setting of test values through a user-friendly interface and efficient communication protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual setting of test output values is performed for each field device, then maintenance accuracy is maintained, but maintenance efficiency deteriorates due to repetitive work
Solution Approach 1:
The maintenance apparatus stores test patterns and test output values in advance in its memory. When performing maintenance on multiple field devices, the apparatus automatically retrieves and applies these pre-stored settings, eliminating the need for manual re-setting of test parameters for each device. This preliminary preparation of test data directly resolves the contradiction by reducing repetitive manual work while maintaining accurate test configurations.
2Measurement precision
If test patterns are customized for each field device, then test accuracy is improved, but device complexity increases due to multiple setting operations
Solution Approach 1:
The maintenance apparatus is designed with universal functionality to handle multiple field devices with different types and specifications. It stores various test patterns and output values applicable to different device types, and automatically selects the appropriate settings based on the connected device. This multi-functional capability allows accurate testing across diverse devices without requiring complex manual configuration for each device type.
Solution Approach 2:
The apparatus copies pre-stored test patterns and output values from its memory to the field devices being tested. Instead of manually creating test settings for each device, the system replicates the appropriate pre-configured test data to multiple devices, ensuring consistent and accurate test parameters are applied across all field devices while simplifying the maintenance operation.
3Productivity
If multiple maintenance workers perform setting work, then maintenance coverage is improved, but coordination complexity increases
Solution Approach 1:
The maintenance apparatus performs self-service by automatically managing test pattern selection and output value setting without requiring manual intervention from maintenance workers. The system autonomously retrieves appropriate test data from its stored patterns, applies them to connected field devices, and executes tests. This automation eliminates the need for multiple workers to coordinate setting operations, reducing coordination complexity while maintaining high maintenance coverage through parallel device testing.
Data Source
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AI summary
A device maintenance apparatus includes a setting operator configured to allow for setting a test pattern, the test pattern being set to define a change of output signals output from a device over time, and an execution operator configured to make the device output the output signals based on the set test pattern.