Scalable HMI Control Template for PLC Memory Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional HMI control templates and PLC configurations face limitations in dynamic adaptability and memory utilization, leading to restricted control and monitoring functions, requiring additional HMI devices and time-intensive programming for enhanced functionality.
Innovation Solution
A programmable logic controller (PLC) with a dynamically scalable HMI control template that allocates memory and control functions individually to each HMI device, allowing real-time data shifting and dynamic assignment of control screens and functions based on workstation identity and tasks, reducing memory usage and increasing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a static HMI template is provided to all networked HMI devices, then memory allocation is simplified, but the range of control and monitoring functions is limited and additional HMI devices are required
Solution Approach 1:
The patent implements a dynamic HMI template system where the PLC generates and distributes customized HMI templates to individual HMI devices based on their specific workstation assignments and required functions. This allows each HMI device to display only the control and monitoring functions relevant to its designated workstation, eliminating the need for a static universal template and expanding the range of available functions without proportionally increasing memory complexity.
Solution Approach 2:
The patent segments the HMI template functionality by workstation and device type, creating modular template components that can be individually assigned to different HMI devices. Each HMI device receives a customized subset of the total available control and monitoring functions, allowing the system to provide comprehensive functionality across multiple devices while optimizing memory utilization at each individual device level.
2Adaptability or versatility
If additional control or monitoring functions are required by an HMI device, then functionality is enhanced, but time-intensive programming and code compilation are required
Solution Approach 1:
The patent implements preliminary configuration where all possible control and monitoring functions are pre-programmed into the PLC's HMI template library during system setup. When an HMI device requires additional functions, the PLC dynamically selects and distributes the appropriate pre-compiled template components to that device, eliminating the need for time-intensive on-demand programming and code compilation while still providing enhanced functionality.
3Stability of the object's composition
If approximately 70% of PLC memory is dedicated to providing a static HMI template to all networked HMI devices, then template consistency is maintained, but memory efficiency is reduced and flexibility is limited
Solution Approach 1:
The patent applies local quality by customizing HMI templates according to the specific needs of each HMI device and its assigned workstation. Instead of providing every device with the complete static template (70% memory allocation), each device receives a customized template containing only the control and monitoring functions relevant to its local operational context, significantly reducing memory usage while maintaining consistency in the overall system architecture and communication protocols.
Solution Approach 2:
The patent creates a universal HMI template library in the PLC that contains all possible control and monitoring functions for the entire process line. This universal library serves all HMI devices through dynamic selection and distribution, allowing the system to maintain template consistency at the architectural level while providing customized functionality at the device level, thereby reducing the 70% memory allocation requirement to a much smaller fraction.
Data Source
AI summary
A method and control system control a process line by providing a PLC with control screens each having a unique screen number. Each HMI device is provided access to a first set of the control screens, with displayed buttons labeled with a corresponding one of the control screens. Input signals are received from a requesting HMI device that identifies the requesting HMI device and requests a control action or a monitoring action for a corresponding workstation. Additionally, the requesting HMI device is provided access to a second set of the control screens based on the received input signals, such that the HMI devices share an HMI control template that is also dynamically and individually scalable to the requesting HMI device. The process line is then controlled via the PLC in response to control signals from the HMI devices corresponding to selections from the control screens.