PLC Configuration Tracking for Manufacturing Line Change Evaluation

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Solution Overview

Problem

Manufacturing lines with programmable logic controllers (PLCs) face challenges in efficiently tracking and evaluating the large number of parameters, making it difficult to monitor and control machines effectively due to the complexity of parameter management.

Innovation Solution

A method and system that utilize processors to obtain and analyze parameter values from PLCs, identify configuration parameters, store timestamped values, and generate hashes to track changes, allowing for predictive performance analysis and adaptive control of machines in manufacturing lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If all parameters from PLC are monitored and stored, then complete machine state tracking is achieved, but computational resources and data storage requirements increase significantly

Engineering Contradiction:

Improvemachine state tracking completenessVSAvoidcomputational resource consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent segments parameters into two categories: configuration parameters (user-manipulatable) and environmental parameters (non-user-manipulatable). This segmentation allows the system to focus computational resources on tracking only the configuration parameters that affect machine behavior, while environmental parameters are monitored but not stored in detail, thus reducing computational load while maintaining reliable state tracking.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent extracts and identifies only the configuration parameters from the full set of PLC parameters by analyzing parameter value differences over time. By taking out only the relevant configuration parameters for detailed tracking and storage, the system reduces data storage requirements and computational resources needed while still achieving complete tracking of machine state changes.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If configuration changes are tracked in detail, then predictive maintenance capability is improved, but system complexity increases

Engineering Contradiction:

Improvepredictive maintenance capabilityVSAvoidparameter management complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent simplifies parameter management by segmenting parameters into configuration and environmental categories. Configuration parameters are tracked in detail with timestamped storage and hash generation for predictive maintenance, while environmental parameters are monitored but managed separately. This segmentation reduces the complexity of parameter management while maintaining the capability for predictive maintenance through focused tracking of configuration changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a simplified representation of parameter changes by generating hash values from configuration parameter sets. Instead of managing and analyzing all raw parameter data, the system uses hash copies to efficiently detect and track configuration changes, reducing system complexity while preserving the ability to perform predictive maintenance analysis.

Inventive Principle:

Principle #26Copying

3Loss of information

If all parameter values are stored with timestamps, then complete audit trail is achieved, but data storage requirements increase

Engineering Contradiction:

Improveconfiguration change audit trailVSAvoiddata storage volume

Core Design Contradiction:

Loss of informationVSQuantity of substance

Solution Approach 1:

The patent extracts only the configuration parameters (user-manipulatable) for detailed timestamped storage and hash generation, while environmental parameters are monitored but not stored with the same level of detail. This extraction approach maintains a complete audit trail for configuration changes while significantly reducing data storage requirements compared to storing all parameters.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses hash values as compact representations of configuration parameter sets. Instead of storing all raw parameter values, the system stores hash copies that efficiently capture the state of configuration parameters at different timestamps, maintaining a complete audit trail while minimizing data storage volume.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS20230063452A1Systems and methods for evaluating configuration changes on a machine in a manufacturing line

Publication Date: 2023.03.02 ATS AUTOMATION TOOLING SYSTEMS INC

AI summary

Systems and methods for evaluating configuration changes on a machine in a manufacturing line are provided. The machine is controlled by a PLC that stores a plurality of parameters associated with the machine. The method involves operating one or more processors to: obtain, from the PLC, a plurality of first parameter values corresponding to the plurality of parameters stored at the PLC at a first time and a plurality of second parameter values corresponding to the plurality of parameters stored at the PLC at a second time; determine a plurality of parameter value differences; identify a plurality of configuration parameters from the plurality of parameters based on the plurality of parameter value differences, each configuration parameter corresponding to a user-manipulatable parameter associated with controlling the machine; and store a plurality of first configuration parameter values in association with a first timestamp corresponding to the first time.