Interactive Wiring Diagram Generation for Industrial Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current industrial automation systems lack an efficient mechanism for dynamically updating electrical CAD drawings in response to changes in plant design, leading to errors, safety risks, and increased downtime.
Innovation Solution
A method and system for automatically generating interactive wiring diagrams using real-time engineering data, which involves determining connections between devices, generating wiring diagrams, and dynamically updating them with device connectivity status information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual updating of electrical CAD drawings is performed repeatedly, then the drawings can be kept updated with design changes, but errors occur frequently and safety risks increase
Solution Approach 1:
The system enables electrical CAD drawings to update themselves automatically by detecting design changes through sensing units and generating updated diagrams without human intervention. The automated system serves itself by continuously monitoring the plant design state and maintaining accurate documentation, thereby eliminating manual errors and safety risks associated with manual updating.
Solution Approach 2:
The system implements continuous feedback loops where sensing units monitor design changes in real-time, transmit data to the processing system, which then updates the electrical CAD drawings and provides visual feedback through the graphical user interface. This closed-loop feedback mechanism ensures the drawings always reflect the current design state, preventing errors from propagating.
2Ease of repair
If manual identification of faulty connections is performed, then fault diagnosis can be conducted, but the process is time-intensive and requires halting plant operation
Solution Approach 1:
The system maintains continuous monitoring of electrical connections through sensing units that operate without interruption during plant production. Fault detection occurs continuously in the background without requiring plant shutdown, allowing useful production activity to continue uninterrupted while diagnostic data is collected and analyzed.
Solution Approach 2:
The system replaces the mechanical manual process of physically tracing and testing electrical connections with an automated electronic monitoring system. Sensing units electronically detect connection status and faults, substituting the manual mechanical diagnostic process with automated electronic detection, thereby eliminating the need to halt production for fault diagnosis.
3Ease of repair
If field operators access cable lines during plant operation for manual diagnosis, then faulty connections can be identified, but the process is dangerous to the life of field operators
Solution Approach 1:
The system performs self-diagnosis by automatically detecting and identifying faulty connections through sensing units without requiring field operator intervention. The automated system monitors connection status continuously and identifies faults independently, eliminating the need for operators to physically access dangerous cable lines during plant operation.
Solution Approach 2:
The system introduces sensing units as intermediary devices that safely interface with electrical connections to detect faults. These intermediary sensors perform the dangerous measurement function remotely, acting as a mediator between the diagnostic system and the hazardous electrical components, thereby protecting field operators from exposure to dangerous cable lines.
4Loss of information
If electrical CAD drawings are updated manually after plant commissioning, then design changes can be tracked, but the process cannot predict downtime and causes difficulty in planning smooth production
Solution Approach 1:
The system performs preliminary detection and documentation of design changes before they impact production. By continuously monitoring through sensing units and automatically updating electrical CAD drawings in real-time, the system proactively identifies potential issues and maintains accurate documentation ahead of time, enabling advance production planning and downtime prediction.
Solution Approach 2:
The system provides continuous feedback on the actual design state through automated monitoring and real-time updates to electrical CAD drawings. This feedback loop supplies current information about design changes and connection status, enabling production planning to be based on accurate, up-to-date information rather than outdated manual documentation.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A method and system (100) for automatically generating interactive wiring diagram in an industrial automation environment is disclosed. The method includes acquiring real-time data associated with devices commissioned in a plant from one or more sensing units disposed at the respective devices. Further, the method includes determining connections between the devices in the plant based on the acquired real-time data using a lookup table. Additionally, the method includes generating a wiring diagram of the plant based on the determined connections between the devices. The wiring diagram represents the devices located in the plant and physical connections between the devices. Moreover, the method includes dynamically generating interactive wiring diagrams by superimposing the wiring diagram with the device connectivity status information associated with respective connections between the devices.