Integrated Maintenance Procedure Guidance for Manual and Automated Tasks

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Solution Overview

Problem

In maintenance operations of plants, existing technologies face challenges in reducing errors in manual maintenance procedures and mistakes in automated maintenance operations due to limitations in executing both manual and automated tasks simultaneously.

Innovation Solution

A maintenance operation support device that combines action definition information and operation definition information to generate and output procedure information, enabling maintenance operators to follow standardized operation procedures, thereby reducing errors and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a device supports only manual maintenance operations, then maintenance operators can perform operations while checking operation manuals and establishing contact with managers, but it is not possible to execute automated maintenance operations, leading to increased number of errors in operation procedures

Engineering Contradiction:

Improveerror reduction in manual operationsVSAvoidautomation capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines manual maintenance operations and automated maintenance operations into a single integrated maintenance device. The device includes both a manual operation support unit that displays operation manuals and guides operators through procedures, and an automated operation execution unit that can automatically perform maintenance tasks on field devices. This merging allows the system to leverage both manual oversight and automated efficiency, reducing errors while maintaining productivity.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If a device supports only automated maintenance operations, then automated execution of maintenance tasks is achieved, but it is not possible to execute manual maintenance operations such as operating valves or establishing contact using transceiver, leading to increased mistakes in operation procedures

Engineering Contradiction:

Improveautomation execution capabilityVSAvoiderror reduction in automated operations

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The integrated maintenance device merges automated operation execution capabilities with manual operation support. The system can automatically execute maintenance operations on field devices through communication interfaces, while simultaneously providing manual operation guidance, displaying operation manuals, and enabling operators to perform manual tasks such as valve operations and transceiver communications. This combination ensures both automation efficiency and manual flexibility are available.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The operation manual display unit and control unit act as intermediaries between the automated system and the human operator. When automated operations are executed, the system can still reference and display relevant operation manual sections, allowing operators to verify automated actions or intervene manually if needed. This intermediary function bridges the gap between automated execution and manual oversight, reducing mistakes in automated operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If maintenance operators perform operations manually by checking operation manuals and establishing contact with managers, then flexibility in handling various maintenance scenarios is maintained, but the number of errors in operation procedures increases

Engineering Contradiction:

Improveflexibility in maintenance operationsVSAvoiderror rate in procedures

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The maintenance device incorporates feedback mechanisms where the control unit monitors the execution status of maintenance operations and provides real-time feedback to the operation manual display unit. The system can track which steps have been completed, highlight current required actions, and alert operators to potential errors. This feedback loop reduces human error by providing continuous guidance and confirmation, while maintaining the flexibility of manual operation decision-making.

Inventive Principle:

Principle #23Feedback

4Speed

If automated maintenance operations are executed without manual support, then execution speed is improved, but mistakes in operation procedures increase due to inability to handle manual tasks

Engineering Contradiction:

Improveoperation execution speedVSAvoidaccuracy of operation procedures

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The system merges high-speed automated operation execution with comprehensive manual support capabilities. The automated unit can quickly execute routine maintenance operations on field devices, while the manual support unit remains available to handle tasks requiring human judgment, such as operating physical valves, communicating via transceiver, or dealing with unexpected situations. This combination achieves both speed and accuracy.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11244265B2Maintenance operation support device, maintenance operation support method, and non-transitory computer readable storage medium

Publication Date: 2022.02.08 YOKOGAWA ELECTRIC CORP

AI summary

A maintenance operation support device includes a procedure information outputter configured to output procedure information representing an operation procedure of maintenance operations for a facility, the procedure information being obtained by combining action definition information for defining actions of a setting tool that adjusts or sets the facility and operation definition information for defining operations to be instructed to a maintenance operator who performs the maintenance operations for the facility.