Numerical Control System HMI Error Switching
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Solution Overview
Problem
Numerical controllers with HMI functional units often experience errors that freeze the display or prevent data update, making it impossible to acquire mechanical information or perform operations on machine tools, as existing solutions only release connections or transmit error signals without ensuring operational recovery.
Innovation Solution
A numerical control system that includes a numerical controller, management terminal, and terminal device connected through a network, allowing the system to detect errors in the HMI functional unit, release connections, and switch the display to a different device for continued operation and data input, using Ethernet interfaces for communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the HMI functional unit is used for display and operation, then the user interface functionality is improved, but when an error occurs in the HMI functional unit, the display freezes or stops updating and operation becomes impossible
Solution Approach 1:
The patent introduces a terminal device as an intermediary that can assume the HMI functional unit's display and operation functions when the original HMI unit fails. The terminal device receives control data from the numerical control unit and displays it, while also accepting operation data from the user and transmitting it back, thus mediating the communication between the numerical control unit and the user when the primary HMI interface is unavailable.
Solution Approach 2:
The system changes the operational state parameter of the HMI interface by switching from a single local display mode to a remote terminal device mode. When an error is detected in the HMI functional unit, the system parameter changes to redirect display and operation functions to the terminal device, thereby maintaining operational continuity despite the error condition.
2Reliability
If the connection to the HMI functional unit is released upon error detection, then the system prevents further errors, but the operation unit cannot restart even after the error is removed
Solution Approach 1:
The terminal device serves as a persistent intermediary that maintains the operation capability even when the local HMI functional unit is disconnected due to errors. While the local HMI connection is released, the terminal device continues to mediate between the numerical control unit and the user, allowing operation to continue without interruption and enabling easy resumption once the local HMI unit recovers.
Solution Approach 2:
The system prepares a backup HMI interface (terminal device) in advance that can immediately take over when the primary HMI functional unit fails. This beforehand cushioning ensures that operation capability is never lost, as the terminal device is already positioned and configured to assume the HMI functions, eliminating any downtime or restart delays.
3Device complexity
If the HMI functional unit integrates both display and operation functions, then the device complexity is reduced, but when it fails, both display and operation are simultaneously lost
Solution Approach 1:
The patent segments the HMI functional unit's functions by separating the display function (handled by the display unit within the HMI functional unit) from the operation function (handled by the operation unit). When an error occurs, the terminal device can independently assume these segmented functions through data communication with the numerical control unit, allowing the system to maintain functionality despite the failure of the integrated HMI unit.
Data Source
AI summary
Provided are a connection unit for connection between a numerical control unit and an HMI functional unit, and a network connection unit for connection to a network. The HMI functional unit includes a display control unit for display on a display unit. The numerical control unit includes: an error detection unit that detects an error in the HMI functional unit; a connection control unit that releases connection to the connection unit and sets up connection to the network connection unit if the error detection unit detects the error in the HMI functional unit; and an alarm notification unit that notifies an alarm to a management terminal.