PLC Display Waveform Pages for Faster Alarm Diagnosis
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Solution Overview
Problem
On-site engineers in factory automation face challenges in diagnosing and quickly resolving issues with programmable logic controllers (PLCs) due to the complexity of ladder programs and the lack of intuitive troubleshooting tools, leading to potential downtime in production lines.
Innovation Solution
A programmable display connected to a PLC that allows users to switch between pages and view device waveforms of chronological data through touch operations, providing essential information for immediate troubleshooting and system recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional alarm lamps are used to indicate troubles, then the system structure remains simple, but on-site engineers cannot diagnose the cause of troubles effectively
Solution Approach 1:
The display screen is divided into multiple functional regions: alarm lamp display region, waveform display region, and parameter display region. Each region presents specific diagnostic information independently, allowing engineers to segment their troubleshooting process by viewing relevant information in each region without being overwhelmed by a monolithic display.
Solution Approach 2:
The system transitions from traditional 2D alarm lamp indicators to a multi-dimensional display approach by adding time dimension through waveform displays showing historical device values. This enables engineers to view not only current alarm states but also temporal patterns of device behavior leading up to the alarm condition.
2Loss of information
If detailed device information is displayed continuously, then diagnostic capability is improved, but the display becomes complex and difficult to operate
Solution Approach 1:
The display system dynamically adapts its content based on alarm conditions. When alarms occur, the display automatically switches to show relevant waveform data and device parameters. During normal operation, the display shows standard monitoring information. This dynamic behavior allows the system to present detailed information only when needed, maintaining ease of operation during normal use while providing comprehensive diagnostics during troubleshooting.
Solution Approach 2:
The system pre-configures multiple display pages with different information layouts and patterns. Engineers can select from pre-defined pages such as alarm detail page, waveform analysis page, and device parameter page. This preliminary preparation of display configurations allows quick switching between different diagnostic views without requiring engineers to manually configure complex display parameters during troubleshooting.
3Adaptability or versatility
If multiple display pages are provided for different functions, then functionality is improved, but switching between pages increases operational complexity
Solution Approach 1:
The display system automatically determines and switches between pages based on detected alarm conditions. When specific alarm patterns are detected, the system autonomously navigates to the most relevant diagnostic page, reducing the need for manual page switching. This self-service behavior simplifies operation while maintaining access to multiple specialized display functions.
Solution Approach 2:
The system provides visual feedback on the display screen indicating which page is currently active and what information is being shown. This feedback mechanism helps engineers understand the current display state and makes navigation more intuitive, reducing the cognitive load associated with managing multiple display pages.
Data Source
AI summary
A programmable display includes a display data generator that generates display data for pages corresponding to their page identifier, a display portion that displays a page corresponding to the page identifier on its display screen based on the display data that is generated by the display data generator, and a touch detector that detects touch operations on the display screen of the display portion. The display portion generates display data for displaying the device wave of the device that is specified by the subject device settings based on the chronological data, which is stored in the PLC, when the touch detector detects a predetermined second touch operation on the display screen. The display portion displays a second page or a device wave on the display screen based on the display data that is generated by the display data generator.