Mobile Operator Console Extension for Remote Process Awareness
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Solution Overview
Problem
Operators in industrial control and automation systems face challenges in maintaining situational awareness and performing routine interventions while stepping away from their consoles, due to increased workload and the need for continuous monitoring, leading to negative impacts on health, well-being, and productivity.
Innovation Solution
The implementation of mobile extensions for industrial operator consoles, which allow operators to maintain situational awareness and intervene in industrial processes remotely, sharing state information with the console and providing location-based functionality through geofencing, enabling operators to move away from their consoles while still managing their responsibilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators continuously monitor industrial processes from fixed operator consoles, then process control reliability is improved, but operator health and well-being deteriorate due to increased workload and inability to take breaks
Solution Approach 1:
The system segments the operator console functionality into a fixed console and a mobile extension device. The mobile extension separates monitoring and control capabilities from the fixed workstation, allowing operators to distribute their attention and physically move away from the console while maintaining process oversight through wireless communication.
Solution Approach 2:
The mobile extension acts as an intermediary between the operator and the industrial control system. It wirelessly transmits process information to the operator and relays control inputs back to the control system, enabling remote monitoring and intervention without direct connection to the fixed console.
2Loss of information
If operators remain at fixed operator consoles for continuous monitoring, then situational awareness is improved, but productivity deteriorates due to inability to collaborate and take breaks
Solution Approach 1:
The system transitions from a static monitoring arrangement to a dynamic one where operators can move freely while maintaining situational awareness. The mobile extension provides real-time process information dynamically updated through wireless communication, allowing operators to change positions, collaborate with colleagues, and take brief breaks without losing awareness of process conditions.
Solution Approach 2:
The mobile extension consolidates multiple functions including process monitoring, alarm notification, control input capability, and communication tools into a single portable device. This multi-functionality enables operators to maintain situational awareness while simultaneously collaborating with teammates and accessing additional resources during breaks.
3Manufacturing precision
If fixed operator consoles are used for process control, then control precision is improved, but device flexibility deteriorates due to operators being stationed at specific locations
Solution Approach 1:
The mobile extension maintains precise control capability through real-time wireless feedback from the industrial control system. Process data, alarm states, and system status are continuously transmitted to the mobile device, allowing operators to make informed control decisions regardless of physical location. Control inputs from the mobile extension are relayed back to the control system with the same precision as fixed console inputs.
Data Source
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AI summary
A system includes an operator console (110) having at least one graphical display (204a, 204b) configured to present information associated with an industrial process and with a control system associated with the industrial process. The system also includes a mobile extension (122) associated with the operator console. The mobile extension is configured to present first process-related information to an operator and receive second process-related information from the operator for the control system. The operator console is configured to provide state information to the mobile extension, where the state information is associated with operations of the operator console. The mobile extension could be configured to base at least part of the first process-related information or at least part of the second process-related information on a location of the apparatus. The operator console could be configured to provide an indication that the mobile extension is currently in use by the operator.