Machine Control Bot Software for Retrofitting Automation
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Solution Overview
Problem
Modern machines for machining and measuring gears lack efficient retrofitting capabilities for network and automation functions, rendering them obsolete despite achieving required quality, due to the impossibility or uneconomical nature of upgrading to modern control systems.
Innovation Solution
Implementing bot software that acts as a 'virtual' machine operator to automate or partially automate machine functions that require manual input, allowing for network and automation functionalities without altering existing control software.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If modern control systems are used to add network and automation functions, then automation capability is improved, but device complexity and cost increase making retrofitting impossible or uneconomical
Solution Approach 1:
A bot software acts as an intermediary layer between the existing control software and the user interface. This bot intercepts and automates manual input sequences without requiring modifications to the underlying control system, thereby adding automation capability while preserving the original simple control architecture.
Solution Approach 2:
The bot software creates a virtual copy of the machine operator by recording and replaying manual input sequences. This allows automated execution of previously manual tasks without changing the original control system, achieving automation through software simulation rather than hardware replacement.
2Extent of automation
If control software is modified to add automation functions, then automation capability is improved, but ease of manufacture and retrofitting worsen due to modification costs
Solution Approach 1:
The automation functionality is segmented into a separate bot software module that operates independently from the existing control software. This segmentation allows the automation features to be added as a standalone component, making retrofitting easy without requiring modifications to the original control system.
Solution Approach 2:
The bot software serves as an intermediary layer that interfaces with the existing control software through the user interface. This approach enables automation addition without penetrating or modifying the original control software architecture, preserving ease of manufacture and retrofitting.
3Ease of operation
If manual input is required for machine functions, then ease of operation is maintained, but productivity decreases due to time-consuming manual operations
Solution Approach 1:
The bot software enables the system to serve itself by automatically performing tasks that previously required manual operator input. The bot records and replays input sequences autonomously, eliminating the need for continuous manual intervention and thereby increasing productivity while maintaining operational simplicity through the bot's self-executing nature.
Solution Approach 2:
The bot creates a virtual copy of the operator's manual input behavior and executes it automatically. This copying of manual operations into an automated sequence maintains the simplicity of the original manual process while eliminating the time consumption, thereby improving productivity without compromising ease of operation.
Data Source
AI summary
A machine for machining and/or measuring gearing, having two or more numerically controlled machine axes for carrying out machining movements and/or measuring movements, having a machine controller, wherein the machine controller has a control software, wherein the control software is set up for executing machine functions, such as executing program sequences for controlling the numerically controlled machine axes, the output of service reports or the like. The machine controller has a user interface set up for interaction with a machine operator, wherein for at least one of the machine functions it is predetermined by the control software that the execution of this machine function requires at least one manual input by a machine operator at the user interface. A bot software is assigned to the control software in order to replace the at least one manual input and to execute the machine function independently of a machine operator.