Production Controller Identifies Stop Cause in Manufacturing Facility
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Solution Overview
Problem
In production facilities, identifying the manufacturing machine causing an operation stop is challenging due to the complexity of processes involved and existing technologies not being able to automatically detect and diagnose the cause of such stops effectively.
Innovation Solution
A production controller that exchanges information with manufacturing machines via communication networks, utilizing stop detection and cause identification algorithms to determine if a production facility has stopped operation and identify the specific machine causing the stop, by analyzing task programs and signal setting information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual identification of the manufacturing machine causing operation stop is performed, then the cause can be identified, but the process becomes complex and time-consuming
Solution Approach 1:
The system enables self-diagnosis by automatically analyzing signal flow and task programs to identify the manufacturing machine causing operation stop, eliminating the need for manual operator investigation and reducing process complexity while maintaining identification accuracy
Solution Approach 2:
The production controller continuously monitors signal exchange between manufacturing machines and provides feedback information about the cause of operation stop, enabling automatic identification through systematic analysis of signal flow and task program states
2Extent of automation
If existing diagnostic techniques are used, then some abnormalities can be detected, but automatic identification of the specific manufacturing machine causing production facility stop is not achieved
Solution Approach 1:
The production controller performs multiple functions including not only controlling manufacturing machines but also automatically analyzing task programs and signal flow to identify the specific machine causing operation stop, consolidating diagnostic capabilities within the existing control system
Solution Approach 2:
The system pre-stores task programs and signal setting information for each manufacturing machine, enabling rapid automatic analysis and identification when an operation stop occurs, without requiring real-time data collection during the diagnostic process
Data Source
AI summary
A cell controller includes a first communication unit which receives a task program and signal setting information stored in each manufacturing machine from this manufacturing machine, a stop detection unit which refers to the task program and the signal setting information to detect whether a production facility has stopped operation, and a stop cause identification unit which analyzes the task program and the signal setting information to identify the manufacturing machine that has caused the operation stop of the production facility, and this cause. Such a cell controller can detect whether a production facility including manufacturing machines has stopped operation, and automatically identify the manufacturing machine that has caused this operation stop, and this cause.