Multi-PLC State Reproduction With Synchronized Waveform Comparison
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Solution Overview
Problem
Existing device state monitoring systems for factory automation (FA) systems with multiple programmable logic controllers (PLCs) require operators to manually investigate signal waveforms, making it time-consuming to analyze control status across multiple PLCs, as they cannot simultaneously compare time-series data values.
Innovation Solution
A device state reproduction device that stores and displays time-series data and sequence programs from multiple PLCs, allowing for simultaneous visualization of data waveforms and program execution states across different PLCs, enabling efficient analysis by reflecting specified time-series data into corresponding sequence programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the collected-data monitoring device displays only On and Off states of signals at cursor positions, then the display structure remains simple, but operators need to understand sequence programs in advance and invest more time to investigate waveform causes
Solution Approach 1:
The patent introduces an intermediary device (the monitoring system with automatic waveform generation capability) that bridges the gap between raw PLC data and operator understanding. This intermediary automatically generates waveform displays from PLC program data without requiring operators to manually interpret sequence programs, thereby reducing analysis time while maintaining ease of operation
Solution Approach 2:
The system performs preliminary action by pre-processing PLC program data into waveform format before the operator needs to analyze it. The monitoring device automatically generates and stores waveform data in advance, so when operators need to investigate signals, the waveforms are already prepared and displayed, eliminating the need for real-time program interpretation
2Productivity
If the monitoring device displays data from a single PLC, then the device complexity remains low, but operators cannot compare time-series data from multiple PLCs simultaneously
Solution Approach 1:
The monitoring device is designed with universality to handle multiple PLCs through a standardized interface. The system can simultaneously connect to and monitor multiple PLCs using the same data acquisition and waveform generation processes, allowing operators to compare time-series data from different PLCs without increasing operational complexity
Solution Approach 2:
The patent merges data from multiple PLCs into a unified display interface. By combining the time-series data from multiple PLCs and presenting them together on single screens with synchronized waveforms, the system enables comprehensive comparison while maintaining a simple user interface that does not increase perceived device complexity
Data Source
AI summary
A program display control unit performs a display process of displaying first time-series data corresponding to a specified time specified by a display time specification unit, on a first sequence program stored in a first device, which is displayed in a second display section, and another display process of displaying second time-series data acquired from a second device of multiple devices, corresponding to the specified time specified by the display time specification unit, on a second sequence program stored in the second device, which is displayed in a third display section.