Production Flow Mapping to HMI Arrays for Consistent SCADA Operation
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Solution Overview
Problem
Complexity and uniqueness of food processing lines make it difficult for operators to control and understand the operation, especially for new operators, due to the time-consuming setup and non-standardized information presentation of existing SCADA systems.
Innovation Solution
A method and system that transform production flow data into human machine interface (HMI) data by identifying storage and processing objects, forming process sequences, and generating aggregated sequences to create a consistent and intuitive operator display, reducing setup time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If SCADA systems are customized to meet specific operator needs, then the systems can be adapted to specific requirements, but new operators have difficulties in understanding the information provided and setup is time-consuming
Solution Approach 1:
The system segments the HMI configuration into standardized functional modules (process sequences, display templates, data bindings) that can be independently configured and reused. This allows customization without requiring complete system setup from scratch, reducing setup time while maintaining adaptability.
Solution Approach 2:
The system provides pre-configured display templates, standard process sequences, and default HMI layouts that are prepared in advance. These preliminary configurations can be directly applied or slightly modified, eliminating the need for operators to build HMI systems from scratch and significantly reducing setup time.
2Adaptability or versatility
If SCADA systems are highly customized for specific needs, then the systems can meet specific requirements, but the information presentation becomes non-standardized and difficult for new operators to understand
Solution Approach 1:
The system implements universal display templates and standardized process sequences that can be applied across different HMI configurations. These standardized elements ensure consistent information presentation regardless of customization level, making the system easier for new operators to understand while still allowing specific adaptations.
Solution Approach 2:
The system enforces homogeneous data representation through standardized templates for displaying process information, alarms, and trends. All HMI screens follow consistent layout patterns, color codes, and information hierarchies, ensuring that new operators can transfer their understanding across different parts of the system.
3Adaptability or versatility
If food processing lines are configured to meet a large variety of conditions, then the lines can produce different products, but the lines become complex and difficult for operators to control
Solution Approach 1:
The control system segments the complex food processing line into modular process sequences, where each sequence represents a discrete functional unit (e.g., heating, cooling, packaging). This segmentation allows operators to manage and understand complex lines by focusing on individual modules rather than the entire system at once.
Solution Approach 2:
The system dynamically adapts the HMI display and control logic based on the current product being produced and the active process sequences. This dynamic behavior allows the same physical line to present different control interfaces for different products, reducing perceived complexity while maintaining versatility.
Data Source
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AI summary
A method (400) for transforming production flow (PF) data (110) into human machine interface (HMI) data (130) is presented. The PF data (110) comprises storage objects (112, 118) and processing objects (114, 116). The method comprises receiving (402) the PF data (110), identifying (404) the storage objects (112, 118) and the processing objects (114, 116) in the PF data (110), for each processing object (114, 116) (406), identifying (408) source objects (112, 114), identifying (410) destination objects (116, 118), forming (412) a number of process sequences (120a-b) based on the PF data (110), identifying (414) linking objects (126a-b) present in two or more of the process sequences (120a-b), generating (416) an aggregated process sequence (128), and generating (418) the HMI data (130) based on the aggregated process sequence (128), such that the HMI data (130) can generate a rectangular array (134), wherein a visually represented destination object (142, 144) of the destination object (116, 118) is placed subsequent to a visually represented source object (138, 140) of the source object (112, 114) for each of the process sequences (120a-b) in the first direction (A) in the rectangular array (134).