Production Flow to HMI Layout for Consistent Line Control
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Solution Overview
Problem
Existing food processing lines are complex and unique, making it difficult for operators to control them, especially when they lack experience with the specific line. Current SCADA systems, while reducing operator burden, require significant time and money to set up and can be confusing for new operators due to varying configurations and information presentation.
Innovation Solution
A method and system for transforming production flow data into human machine interface (HMI) data, which involves identifying storage and processing objects, forming process sequences, linking them to create an aggregated sequence, and generating HMI data that presents the food processing line in a consistent, intuitive manner on an operator display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If food processing lines are configured to meet a large variety of conditions and requirements, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by creating a standardized HMI framework that can be used across different food processing line configurations. The method transforms diverse production flow data into a consistent visual representation format, allowing the same interface structure to handle multiple product types and processing configurations without requiring custom interfaces for each scenario.
Solution Approach 2:
The patent uses parameter changes by dynamically adjusting the visual representation parameters based on the underlying process data while maintaining the same structural framework. The HMI system changes parameters such as displayed values, connection paths, and process sequences based on the specific processing line configuration, allowing adaptability without increasing structural complexity.
2Ease of operation
If SCADA systems are set up according to specific operator needs, then ease of operation is improved, but loss of time increases due to setup time and operator training time
Solution Approach 1:
The patent applies preliminary action by pre-establishing a standardized HMI framework and transformation methodology that can be directly applied to any food processing line configuration. The system includes pre-defined visual representation patterns and transformation rules that eliminate the need for time-consuming custom setup for each new processing line, reducing both initial configuration time and operator training time.
Solution Approach 2:
The patent uses copying by creating visual representations that follow standardized templates and patterns. The HMI system copies proven effective display structures across different processing line configurations, eliminating the need to create unique interfaces for each scenario and significantly reducing setup and training time while maintaining ease of operation.
3Ease of operation
If SCADA systems are set up according to specific operator needs, then ease of operation is improved, but reliability deteriorates due to potential operator mistakes from non-optimal control understanding
Solution Approach 1:
The patent applies homogeneity by ensuring consistent visual representation of process information across all operating scenarios. This consistency reduces the cognitive load on operators and eliminates confusion that could lead to mistakes, while still providing the necessary operational flexibility. The uniform structure helps operators reliably interpret process states regardless of the specific processing line configuration.
Data Source
AI summary
A method for transforming production flow data into human machine interface data is presented. The PF data comprises storage objects and processing objects. The method comprises receiving the PF data, identifying the storage objects and the processing objects in the PF data, for each processing object, identifying source objects, identifying destination objects, forming a number of process sequences based on the PF data, identifying linking objects present in two or more of the process sequences, generating an aggregated process sequence, and generating the HMI data based on the aggregated process sequence, such that the HMI data can generate a rectangular array, wherein a visually represented destination object of the destination object is placed subsequent to a visually represented source object of the source object for each of the process sequences in the first direction in the rectangular array.