Portable PLC Interface Assembly for Offsite Line Verification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Assembly lines in manufacturing processes face challenges in verifying the functionality of machines and systems like AVI and QIS when the assembly line is offsite, as it is impractical to physically move the entire line for testing and synchronization.
Innovation Solution
A portable interface assembly with programmable logic controllers and a human machine interface allows for remote simulation of data, enabling users to select build styles, input line speed, and control data, which is then converted into simulated data to test machine operations without physically moving the assembly line, using relays and other hardware components to mimic machine side relays and protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the assembly line is moved to the final location for verification, then the functionality of machines and systems can be tested, but the complexity and cost of relocation increases
Solution Approach 1:
The patent creates a portable interface assembly that generates simulated AVI and QIS data to mimic the behavior of the actual assembly line systems. This copy allows verification of machine functionality without physically relocating the entire assembly line, thereby maintaining reliability while avoiding relocation complexity
Solution Approach 2:
The portable interface assembly acts as an intermediary device between the machines and the control systems. It receives simulated data inputs and translates them into the specific data formats required by the machines, enabling verification without direct connection to the actual AVI and QIS systems that would require full assembly line relocation
2Reliability
If the entire assembly line is relocated for testing, then comprehensive verification is possible, but the time and resources required increase significantly
Solution Approach 1:
Instead of relocating the entire assembly line, the invention uses simulated data copies of AVI and QIS information to verify machine functionality. This allows comprehensive system verification to be performed at the offsite location without the time-consuming process of physically moving the assembly line
Solution Approach 2:
The portable interface assembly is configured with pre-programmed capabilities to generate simulated data and interface with machines before the assembly line is fully installed. This preliminary verification action saves time by identifying and resolving issues early in the setup process, avoiding delays that would occur if verification had to wait until after full relocation
3Ease of operation
If simulated data is used to verify machine operations, then the assembly line can remain stationary, but the accuracy of verification may be compromised
Solution Approach 1:
The portable interface assembly is designed to handle multiple data formats and simulation scenarios. It can generate simulated AVI data, simulated QIS data, and interface with various machine types using different communication protocols. This multi-functionality ensures that simulated data verification maintains accuracy across diverse verification scenarios while enabling remote operation
Solution Approach 2:
The system incorporates feedback mechanisms where the portable interface assembly receives responses from the machines and validates them against expected outcomes. This feedback loop ensures that simulated data verification maintains measurement precision by continuously checking that machine responses match the predicted behavior based on the simulated inputs
Data Source
AI summary
Embodiments herein are directed to an assembly having a plurality of machines, a first programmable logic controller device and a second programmable logic controller device commutatively coupled to the first programmable logic controller device. The second programmable logic controller device includes a human machine interface having a display and displaying a plurality of user inputs. A processing device communicatively coupled to the display and a storage medium. The storage medium includes one or more programming instructions that, when executed, cause the processing device to prompt a user to select a desired program, to input a desired line speed time, and to input a plurality of line control data. The data is converted into a simulated data and transferred to the first programmable logic controller device, which causes at least one machine of the plurality of machinery to move in a predetermined manner based on the simulated data.