Mobile Plant Control With Localization-Based Area Assignment
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Solution Overview
Problem
In large industrial systems, decentralized input and output devices are complex and inflexible, leading to potential incorrect assignment and operating errors when used for system control, especially with mobile devices.
Innovation Solution
A system control method utilizing mobile input and output devices, such as smartphones, that employ identification and localization technologies like NFC tags or QR codes to ensure precise assignment and operation, integrating with a programmable logic controller via a field bus system and local area network, ensuring correct system area or component interaction and safety through emergency stop functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If decentralized input and output devices are provided in sub-areas of the plant, then local monitoring and control capability is improved, but device complexity and assignment correctness deteriorate
Solution Approach 1:
The mobile device serves multiple functions: it acts as both an information display device and a command input device across different plant areas. Instead of providing separate fixed devices for each location, a single mobile device can be moved throughout the plant, reducing the total number of devices while maintaining comprehensive monitoring and control capability.
Solution Approach 2:
The system transitions from static fixed devices to a dynamic mobile device that can be relocated. The mobile device dynamically adapts to different plant areas through operator movement, and the system dynamically updates the association between the mobile device and current plant area based on localization data, enabling flexible monitoring and control without requiring fixed device installations at every location.
2Adaptability or versatility
If mobile input and output devices are used, then flexibility and ease of operation are improved, but risk of incorrect assignment and operator errors increases
Solution Approach 1:
The system continuously receives localization data from the mobile device and dynamically updates the association between the mobile device and the current plant area. This feedback mechanism ensures that the system always knows which plant area the mobile device is currently associated with, preventing incorrect assignments. The control unit uses this feedback to route commands and information correctly based on the mobile device's current location.
Solution Approach 2:
Before the mobile device can issue commands or access information, the system performs preliminary verification by checking the localization data to establish correct association with the plant area. This preliminary action ensures that the mobile device is properly assigned to the current plant area before any control operations are permitted, preventing operator errors due to incorrect assignment.
3Reliability
If fixed assignment of devices to plant areas is implemented, then assignment correctness is improved, but flexibility and adaptability deteriorate
Solution Approach 1:
The system replaces static fixed device assignments with dynamic mobile device assignments. The mobile device's association with plant areas is not predetermined but is dynamically established based on real-time localization data. This allows the system to maintain correct assignment (through continuous localization tracking) while simultaneously providing flexibility (through mobile device movement and repositioning).
Data Source
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AI summary
The present invention relates to a plant control system, in particular for controlling conveyor systems (8, 9), comprising at least one mobile input and/or output device (10) and at least one control unit (1) for controlling the plant and for receiving and/or transmitting signals from and/or to the mobile input and/or output device, wherein a signal transmission device (2, 3, 6, 7) for signal transmission between the mobile input and/or output device and the control unit is configured such that the signal transmission is at least partially wireless, wherein the plant control system comprises one or more identification and localization devices (11, 13) which are configured to cooperate with the mobile input and/or output device in order to locate the position of the mobile input and/or output device on the plant and to identify the corresponding plant area.Furthermore, the invention relates to a method for mobile plant control.