Remote Module Grouping for Faster Production Line Start-Up Checks
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Solution Overview
Problem
The existing production line start-up process is cumbersome due to the need for individual monitoring and checking of multiple remote modules, which requires complex control programs and lengthy execution times, especially when dealing with a large number of modules.
Innovation Solution
A production assisting device that collects module identification information, groups remote modules, sets operation modes, and displays operation information for each group, allowing for collective checking and simplifying the start-up process by enabling remote modules to operate in a unified mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual monitoring of each remote module is performed, then operational checking completeness is improved, but work time and complexity increase
Solution Approach 1:
The patent combines multiple remote modules into a single group and monitors them collectively through one control program. Instead of creating separate control programs for each remote module, the system groups them (e.g., Group 1, Group 2) and executes unified monitoring operations, thereby reducing the total number of operations required while maintaining complete operational coverage of all modules.
Solution Approach 2:
The control program is designed with universal functionality to handle multiple remote modules simultaneously. A single control program can monitor any number of remote modules by iterating through grouped module identifiers, making the system adaptable to different configurations without requiring program modifications for each individual module.
2Loss of time
If control program is created for collectively monitoring multiple remote modules, then work time is reduced, but program complexity increases
Solution Approach 1:
The patent segments remote modules into distinct groups (e.g., Group 1 containing Remote Modules 1-5, Group 2 containing Remote Modules 6-10) and processes each group separately within the control program. This segmentation allows the complex monitoring task to be divided into manageable segments, reducing overall program complexity while enabling collective monitoring of all modules.
Solution Approach 2:
The control program implements periodic action by systematically iterating through each group and its constituent remote modules in a structured sequence. The program cycles through groups and modules using loops and counters, providing a rhythmic, organized approach to monitoring that simplifies the control logic compared to handling each module independently.
3Reliability
If ten remote modules are monitored individually, then operational checking completeness is improved, but number of operations increases
Solution Approach 1:
The patent merges the monitoring operations for ten remote modules into a single collective operation. Instead of executing ten separate read-display-check cycles, the system groups the modules and performs one unified monitoring operation that iterates through all modules in the group, reducing the total number of discrete operations from ten to one while ensuring all modules are checked.
Data Source
AI summary
A terminal (100) includes a start assist tool (120) that classifies, into multiple groups, multiple remote modules (400) including channels (CH) connected to production line devices (500) as control targets, sets, based on information about the groups, an operation mode of a remote module belonging to a specific group of the multiple groups to a first operation mode to perform operational checks, and forms an image to display an operation of the remote module belonging to a first group.