PLC Positioning Device Using Pre-Analyzed Operation Patterns
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Solution Overview
Problem
Existing PLC systems face challenges in shortening the positioning start time, which can lead to increased takt time and performance degradation, especially in systems that frequently restart positioning operations.
Innovation Solution
A positioning device with a computing unit that analyzes positioning start instructions, a storage unit for operation patterns and analysis results, and an instruction generating unit that uses stored analysis results to generate positioning data when the operation pattern is recognized, thereby omitting redundant data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data analysis is performed for each positioning start instruction, then positioning accuracy is ensured, but positioning start time increases
Solution Approach 1:
The system performs data analysis in advance by storing operation patterns and their corresponding analysis results in a storage unit. When a positioning start instruction is received, the system checks whether the instruction matches a stored operation pattern. If a match is found, the pre-analyzed data is reused, eliminating the need for redundant analysis and thus shortening the positioning start time while maintaining positioning accuracy.
2Adaptability or versatility
If the number of positioning functions is increased, then positioning capability is improved, but positioning start time increases
Solution Approach 1:
The system stores multiple operation patterns with their analysis results in advance. When a positioning start instruction is received, the system checks whether the instruction matches a stored operation pattern. If a match is found, the pre-analyzed data is reused, eliminating the need for redundant analysis and thus shortening the positioning start time while maintaining positioning accuracy.
Solution Approach 2:
The system creates copies of analysis results for different operation patterns and stores them in the storage unit. Instead of performing full data analysis for each positioning instruction, the system copies and reuses the stored analysis results that correspond to matching operation patterns, significantly reducing the computation time while handling multiple positioning functions.
3Productivity
If positioning operations are frequently restarted, then production efficiency is improved, but positioning start time becomes a limiting factor
Solution Approach 1:
The system performs data analysis in advance by storing operation patterns and their corresponding analysis results in a storage unit. When a positioning start instruction is received, the system checks whether the instruction matches a stored operation pattern. If a match is found, the pre-analyzed data is reused, eliminating the need for redundant analysis and thus shortening the positioning start time while maintaining positioning accuracy.
Solution Approach 2:
The system maintains continuous operation by storing analysis results for frequent positioning patterns. When positioning operations are restarted, the system quickly retrieves pre-analyzed data from the storage unit, ensuring that the useful action of positioning continues without interruption or delay, thereby improving production efficiency.
Data Source
AI summary
A positioning device and a programmable logic controller (PLC) system including the positioning device are provided. The positioning device includes a computing unit that analyzes a positioning start instruction that includes an operation pattern, a storage unit that stores therein an operation pattern and an analysis result obtained by the computing unit analyzing the operation pattern stored in the storage unit in association with each other, and an instruction generating unit including a processor that, when it is verified that the operation pattern stored in the storage unit corresponds to the operation pattern included in the positioning start instruction, reads the analysis result associated with the operation pattern stored in the storage unit and generates positioning instruction data for positioning a control target by using the read analysis result.