PLC-Guided Machine Commissioning With Status-Based Work Instructions
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Solution Overview
Problem
Current commissioning processes for complex machines in the liquid food industry are prone to errors due to reliance on operator experience and lack of systematic documentation, leading to potential safety issues and performance impairments.
Innovation Solution
A method and machine that utilize a programmable logic controller (PLC) with a commissioning status flag to ensure each component is properly commissioned, allowing for automated documentation and instruction delivery through an edge device and input/output unit, ensuring comprehensive and transparent documentation of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If commissioning is performed based on operator experience, then commissioning can be completed, but deviations from manufacturer recommendations occur leading to safety risks and performance issues
Solution Approach 1:
The patent applies preliminary action by pre-defining all necessary commissioning steps, checks, and documentation requirements in a structured commissioning plan before the actual commissioning process begins. This ensures that operators follow manufacturer recommendations systematically rather than relying on individual experience, thereby improving commissioning quality while maintaining ease of operation through clear guidance.
Solution Approach 2:
The patent implements feedback mechanisms through systematic documentation and verification steps that track whether each commissioning requirement has been met. This feedback loop ensures deviations from manufacturer recommendations are immediately identified and corrected, improving reliability without complicating the commissioning process for operators.
2Reliability
If extensive testing is performed to ensure proper commissioning, then commissioning quality improves, but commissioning time increases significantly
Solution Approach 1:
The patent segments the commissioning process into distinct, manageable steps and checks that can be performed systematically. By dividing comprehensive testing into structured segments with clear completion criteria, the patent ensures thorough commissioning quality while allowing parallel execution of tasks and reducing overall commissioning time through organized workflow management.
Solution Approach 2:
The patent applies preliminary action by pre-organizing all testing requirements, checklists, and documentation templates before commissioning begins. This preparation allows commissioning engineers to execute tests efficiently without time-consuming planning during the actual commissioning process, maintaining high quality while reducing total commissioning time.
3Loss of information
If detailed documentation of the commissioning process is maintained, then traceability and troubleshooting capability improve, but documentation effort and complexity increase
Solution Approach 1:
The patent applies self-service by designing a documentation system that automatically captures commissioning data, test results, and completion status during the commissioning process itself. This eliminates the need for separate manual documentation efforts, reducing the complexity burden on operators while ensuring complete traceability and information retention through automated recording.
4Reliability
If comprehensive commissioning checks are performed on all PLC blocks, then commissioning quality improves, but the complexity of tracking and managing commissioning status increases
Solution Approach 1:
The patent implements feedback mechanisms that automatically track and report the commissioning status of each PLC block. This systematic feedback system provides real-time visibility of commissioning progress and completeness without requiring complex manual tracking, thereby ensuring comprehensive commissioning quality while keeping the management system simple and manageable through automated status monitoring.
Data Source
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AI summary
The invention relates to a machine and a method for operator-guided commissioning of the machine, in particular a machine in a machine line for filling and packaging food and/or beverages. The invention reads out a commissioning status for modules in a programmable logic controller (PLC) of the machine. The commissioning status of a module is stored in the PLC and indicates whether or not the module has already been commissioned. The commissioning status for the module is transmitted to a server, and if the commissioning status indicates that the module has not yet been commissioned, one or more instructions are received from the server. The received instructions can be output to a user. The commissioning status for the module is changed in the PLC based on a user action.