Operator Station Visualization Check for Accessible Installation Images
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Solution Overview
Problem
Existing control systems for manufacturing and process installations cannot assess the individual and environment-dependent accessibility of configured installation images during operation and monitoring, as they do not account for factors like operator vision, output devices, and ambient conditions.
Innovation Solution
A control system that generates a test image at runtime, comprising colors, fonts, and flashing frequencies from the installation images, allowing operators to check and correct the visibility of these elements, and requires acknowledgment of a test image before presenting actual installation images for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If installation images are configured during engineering with centralized color schemes and symbolic colors, then the visualization information can be systematically organized and consistently applied across different installation images, but the individual and environment-dependent accessibility of these installation images cannot be assessed during operation and monitoring
Solution Approach 1:
The control system automatically generates a test image that previews all visual elements (colors, fonts, flashing frequencies) from the installation images before the operator actually uses them. This preliminary visualization allows assessment of accessibility under current environmental conditions without requiring reconfiguration of the installation images themselves.
Solution Approach 2:
A test image is introduced as an intermediary element between the installation images and the operator. This test image contains extracted visual elements (colors, fonts, flashing frequencies) that serve as a preview or representation, allowing the operator to assess accessibility without directly examining the complex installation images or modifying them.
2Ease of operation
If installation images are configured during engineering without knowing all boundary conditions, then the engineering process can be completed efficiently, but the installation images cannot be checked for accessibility under all usage conditions
Solution Approach 1:
The system performs preliminary extraction of visual elements (colors, fonts, flashing frequencies) from installation images and generates a test image before the operator needs to assess accessibility. This allows on-demand checking without requiring time-consuming reconfiguration or reconstruction of installation images during operation.
Solution Approach 2:
Instead of requiring the operator to examine the original complex installation images, the system creates a simplified copy or representation in the form of a test image that contains all relevant visual elements. This test image can be generated quickly and examined for accessibility without the time cost of analyzing the full installation images.
3Reliability
If the control system presents installation images directly to the operator, then the operator can immediately access the visualization information, but the operator cannot assess whether all visual elements are perceivable under current environmental conditions
Solution Approach 1:
Before presenting installation images for safe operation, the system preliminarily generates a test image that allows the operator to verify accessibility. The test image serves as a safety check, ensuring that visual elements can be perceived under current environmental conditions before the operator relies on them for safe operation.
Solution Approach 2:
The test image acts as an intermediary safety mechanism between the installation images and the operator. It provides a preliminary assessment layer that verifies accessibility without blocking access to the actual installation images, thus maintaining operational capability while enhancing safety.
Data Source
AI summary
A control system for a manufacturing or process installation includes at least one operator station server and at least one operator station client connected to the operator station server, wherein the operator station server is configured to transfer visualization information to the operator station client, where the visualization information comprises a plurality of exchangeable installation images and where the operator station client is configured to present the visualization information with the exchangeable installation images to an operator of the manufacturing or process installation, where the control system is configured to present the operator of the manufacturing or process installation, at the runtime of the manufacturing or process installation, with a test image that differs from the installation images and that comprises a color region having the colors used in at least two of the installation images of the visualization information.