Integrated HMI-PLC Control for Deterministic Manufacturing Safety
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Solution Overview
Problem
The complexity and cost of automation control systems in manufacturing environments are increased due to the separation of human-machine interfaces and programmable logic controllers, with inefficiencies in programming languages and network connectivity leading to suboptimal performance, particularly in time-critical safety applications.
Innovation Solution
A consolidated human-machine execution system that integrates the human-machine interface, safety features, and complex logic into a single system using an Intel-based computer with a microcontroller and custom firmware, supporting modern programming languages like C++ and C#, enabling deterministic control and rapid development and deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human-machine interface and programmable logic controller are separated into discrete systems, then system functionality is enhanced, but device complexity and cost increase
Solution Approach 1:
The patent consolidates the human-machine interface, programmable logic controller, and safety systems into a single integrated controller. This merging eliminates the need for separate discrete systems while maintaining all required functionalities, thereby reducing device complexity and cost without sacrificing system capability.
Solution Approach 2:
The integrated controller is designed to perform multiple functions simultaneously: it serves as both the human-machine interface and the programmable logic controller, and incorporates safety system capabilities. This multi-functionality allows a single device to replace multiple specialized components, resolving the contradiction between enhanced functionality and increased complexity.
2Adaptability or versatility
If traditional programming languages and network protocols are used for connectivity, then system compatibility is maintained, but productivity and response time deteriorate
Solution Approach 1:
The patent employs modern programming languages (C++, C#) instead of traditional ladder logic, and utilizes contemporary network protocols (Ethernet, TCP/IP) rather than legacy communication methods. These parameter changes in the technological stack significantly improve compilation speed, execution efficiency, and network bandwidth utilization, thereby enhancing productivity while maintaining compatibility through standardized interfaces.
3Speed
If network bandwidth is increased to handle data from numerous devices, then data transfer capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts critical safety and control functions from the networked data stream and processes them locally within the integrated controller. By handling time-sensitive operations locally rather than relying on network communication, the system reduces the bandwidth requirements for network infrastructure while maintaining high data transfer capability for non-critical data.
Data Source
AI summary
An integrated human-machine execution system and related method for manufacturing automation, includes a computer, a graphical user interface, one or more programmable input/outputs, one or more human-machine interface components, and a network adapter. The computer is enabled to execute all necessary software to operate the functions of the integrated system and orchestrate the execution of one or more automated manufacturing operations. In some examples, data updates are event-based instead of time-based such that data updates transmitted by the system when data value changes initiate an event, independently of time elapsed since occurrence of a prior event. The system can be configured to connect to an external and discrete programmable logic controller attached an automation component and instructions to the automation component are instantiated at the human-machine execution system, obviating the need for programming at the programmable logic controllers.