Shared-Status Control for Reliable Production Data Storage
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Solution Overview
Problem
Existing data collection systems in production sites face reliability issues, which can lead to failures in product shipment due to incomplete or unreliable data storage, particularly with the increasing volume and variety of data being collected, including image data.
Innovation Solution
A control device with a data collector and manager that shares status monitoring information to ensure data storage completion, allowing controlled data collection triggers and reliable data storage through shared information access, including time stamps and usage rates, to confirm data storage readiness before proceeding with next processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data collection is performed more frequently and with greater variety (including image data), then the availability and traceability of production data is improved, but the reliability of data storage and collection becomes worse due to increased complexity and potential failures
Solution Approach 1:
The control device is divided into distinct functional modules: a data collection module that gathers data from multiple sources (including image data), a data management module that handles storage coordination, and a shared information area that separates collection status from control logic. This segmentation isolates complexity within specific modules while maintaining overall system reliability through modular error containment and independent operation.
2Quantity of substance
If data is stored in external storage connected over network, then data capacity and accessibility are improved, but data storage completion confirmation becomes more difficult and less reliable
Solution Approach 1:
The system implements a feedback mechanism where the data collection module writes completion status information to a shared information area after successfully storing data in external storage. The control module continuously monitors this shared information area to confirm storage completion. This feedback loop provides reliable confirmation of storage status even when storage is performed over a network, ensuring data integrity before proceeding with subsequent processing steps.
3Productivity
If data storage completion is not confirmed before next processing, then productivity is improved by reducing waiting time, but data traceability and reliability deteriorate due to potential data loss or incomplete storage
Solution Approach 1:
The system performs preliminary storage completion confirmation by continuously monitoring the shared information area before initiating the next processing step. The control module checks the completion status flag in advance, ensuring data is fully stored and verified before proceeding. This preliminary action prevents data loss and maintains traceability while minimizing waiting time through efficient status checking protocols.
Data Source
AI summary
A control device includes a control operation performing unit that performs control operation on a control target in accordance with a user program, a data collector that collects one or more pieces of data designated in advance and has the data stored in a storage designated in advance, and a data manager that manages shared information that can be accessed by the control operation performing unit and the data collector. The data collector writes into the shared information, information indicating completion of storage of data in the storage. In the user program executed by the control operation performing unit, the shared information can be referred to.