Group-Based Control Device for Abnormality Management
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Solution Overview
Problem
As the number of control target devices increases in production facilities, the complexity of user program design and maintenance grows, making it difficult to efficiently manage and modify programs, especially when new devices are added or network configurations change, which hinders the implementation of fail-safe and interlock functions during device abnormalities.
Innovation Solution
A control device that classifies control target devices into groups, allowing for abnormality detection and controlled actions within these groups, including stopping or continuing operations based on predefined conditions, and managing dependence relationships between groups to simplify user program design and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of control target devices is increased to enhance production facility scale and speed, then productivity is improved, but device complexity increases and user program design becomes significantly more difficult
Solution Approach 1:
The patent segments control target devices into multiple groups (first group, second group, etc.) based on their functional relationships and interlocks. This segmentation allows the control system to manage a large number of devices by dividing them into smaller, more manageable units, reducing the complexity of user program design while maintaining the ability to control all devices effectively.
Solution Approach 2:
The patent introduces a new dimension of organization by classifying devices into groups with different interlock relationships. Instead of managing devices individually in a flat structure, the system creates a hierarchical dimension where devices are organized into groups, and interlocks are defined between groups rather than between individual devices, simplifying the overall control architecture.
2Adaptability or versatility
If new devices are added or network configuration is changed after user program is produced, then adaptability is improved, but a large amount of man-hour is expended to modify the user program
Solution Approach 1:
By segmenting devices into groups, the system allows configuration changes to be made at the group level rather than requiring modifications to individual device programs. When new devices are added, they can be assigned to existing groups or new groups without requiring changes to the core user program logic, significantly reducing modification time.
Solution Approach 2:
The patent creates universal group definitions that can accommodate multiple types of devices within the same group. This universality allows the system to handle different device types and configuration changes through a standardized group-based approach, eliminating the need to modify user programs when adding new devices or changing network configurations.
3Quantity of substance
If the number of variables used in PLC increases markedly due to large number of control target devices, then device coverage is improved, but design work efficiency of user program deteriorates
Solution Approach 1:
The patent merges multiple device variables into group-level variables. Instead of managing individual variables for each control target device, the system combines devices within groups and uses group-level interlock definitions. This merging reduces the number of variables that need to be managed in user programs while maintaining comprehensive control over all devices.
Solution Approach 2:
Group definitions serve as universal templates that can be applied to multiple devices with similar functions. Once a group is defined with its interlock relationships, this definition can be reused across different devices, eliminating the need to create individual variable definitions for each device and significantly improving design work efficiency.
4Extent of automation
If devices are centrally managed in PLC, then control capability is improved, but fail-safe function and interlock function become difficult to implement during device abnormality
Solution Approach 1:
The patent segments the centralized control system into group-based control units. Each group can be independently monitored and controlled, allowing fail-safe functions to be implemented at the group level. When an abnormality occurs in one device, the system can identify the affected group and apply interlock functions specifically to that group without disrupting the entire centralized control system.
Solution Approach 2:
The patent introduces groups as intermediary layers between individual devices and the centralized PLC control. These groups act as mediators that aggregate device-level information and apply control logic at an intermediate level, enabling more effective fail-safe and interlock functions by providing better visibility and control over device relationships during abnormal conditions.
Data Source
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AI summary
At least some of plural control target devices are classified so as to belong to one of plural groups. A control device holds identification information specifying a belonging control target device and information about a behavior of a remaining control target device in detecting an abnormality of a control target device belonging to an identical group with respect to each group. The control device detects the abnormality of each of the plural control target devices based on data exchanged with the plural control target devices in executing a user program. When the abnormality is detected in one of the plural control target devices, the control device refers to the identification information to specify an abnormal group to which the control target device in which the abnormality is detected belongs, and the control device refers to the information about the behavior to control action of the abnormal group.