Remote Foundry Assistant Using Mobile Terminals for PLC Diagnostics
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Solution Overview
Problem
Existing remote maintenance systems are inadequate for large foundries with multiple molding machines and lines, as they struggle to accurately detect and address issues due to fixed cameras, complex layouts, and the presence of multiple PLCs, posing safety risks during urgent repairs.
Innovation Solution
A remote assistant system with a touchscreen panel, sequencers, mobile computers, and wireless communication, allowing for video and voice information collection and transmission, along with ladder logic program access, to guide operators in troubleshooting and repairing molding machines and lines safely, using additional motion sensors for enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a fixed video camera is used for remote monitoring, then the system structure is simple, but it cannot detect all locations of trouble in a large plant with complex layout
Solution Approach 1:
The monitoring system is divided into multiple portable terminals that can be distributed to different locations. Each terminal captures images locally, and the images are transmitted to the remote assistant. This segmentation allows comprehensive coverage of large areas without requiring a single complex fixed camera system.
Solution Approach 2:
The system uses portable terminals that can be dynamically moved to different locations as needed, rather than fixed cameras with static positions. This dynamic approach allows the monitoring coverage area to be flexibly adjusted based on the specific troubleshooting needs and plant layout variations.
2Adaptability or versatility
If multiple PLCs are installed in molding machines, then the control functionality is enhanced, but information from multiple PLCs cannot be effectively utilized for remote assistance
Solution Approach 1:
The portable terminal is designed to universally connect to and read data from multiple different PLCs using standard communication protocols. This multi-functional capability allows the terminal to access information from any PLC in the system, regardless of which specific PLC is controlling which machine, thereby utilizing all available PLC information for remote assistance.
Solution Approach 2:
The portable terminal acts as an intermediary device between the multiple PLCs and the remote assistant. It collects information from various PLCs, standardizes the data format, and transmits it to the remote location, enabling effective utilization of information from multiple PLCs without requiring direct connections from each PLC to the remote system.
3Object-affected harmful factors
If the video camera is located far from the machine, then the safety distance is maintained, but it is difficult to quickly realize the cause of the trouble
Solution Approach 1:
The portable terminal captures high-resolution images of the machine and transmits them to the remote assistant, creating a visual copy of the actual machine state. This allows the remote assistant to closely examine the machine condition without being physically close, maintaining safety distance while enabling rapid diagnosis through detailed image analysis.
Solution Approach 2:
The system replaces the need for physical proximity with electronic image transmission. Instead of requiring the assistant to be mechanically close to the machine for visual inspection, the system uses digital image copying and transmission to provide equivalent diagnostic capability from a safe distance, thereby eliminating the trade-off between safety distance and diagnosis speed.
4Measurement precision
If ladder logic program information is used for repairs, then the repair accuracy is improved, but unexpected circumstances may occur without safety checks
Solution Approach 1:
The system performs preliminary safety checks by capturing images of the machine state and transmitting them to the remote assistant before any repair actions are taken. The remote assistant can review the images and provide safety instructions based on the actual visual condition, ensuring that safety checks are completed in advance before using ladder logic information for repairs.
Solution Approach 2:
The system establishes a feedback loop where images of the machine are continuously transmitted to the remote assistant, who provides real-time guidance and safety checks based on the visual information received. This feedback mechanism ensures that repair actions are guided by both ladder logic information and actual visual observation, maintaining both repair accuracy and safety reliability.
Data Source
AI summary
The object of the present invention is to provide a remote assistant system for a foundry, i.e., a plant that comprises a plurality of machines. The remote assistant system in a foundry includes a first sequencer for controlling a molding line and a second sequencer for controlling a molding machine. It further includes a sequencer-communicating means for connecting the first sequencer to the second sequencer, a first mobile computer for transmitting information by video images, etc., to a remote location, a means for providing communication between mobile computers to selectively connect one of the sequencers to the first mobile computer, a second mobile computer for receiving the information from the first mobile computer, for displaying the information, and for correcting the ladder logic program and giving instructions to the operator by an assistant at a remote location.