Simulated Machine Operation Screen for Non-Invasive Data Extraction
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Solution Overview
Problem
In manufacturing industries, site working staff face challenges in controlling machine controllers while using non-invasive data-extraction systems, as they cannot view machine states and data in real time due to the need to pause data extraction processes.
Innovation Solution
A system module that simulates the machine operation screen, using an image capture device, high-speed image process unit, and software control system to extract and transmit operational information in real time, allowing for continuous monitoring and control without interrupting data extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the data-extraction system continuously extracts data from the machine controller screen, then real-time machine state monitoring is achieved, but the site working staff cannot control the machine controller simultaneously
Solution Approach 1:
The system creates a simulated operation screen that copies the visual display of the machine controller. This simulated screen is generated by capturing the actual screen display and processing it to create a duplicate visual representation that can be viewed simultaneously without interfering with the original controller operation.
Solution Approach 2:
The system introduces an intermediary simulated operation screen between the staff and the machine controller. This intermediary interface allows the staff to view machine state information through the simulated screen while maintaining direct access to control the actual machine controller, thus mediating the conflict between monitoring and controlling functions.
2Productivity
If the site working staff switches operation screens to extract machine data, then data extraction is performed, but the staff cannot control the machine during screen switching
Solution Approach 1:
Instead of requiring staff to switch screens on the actual controller, the system creates a copied simulated screen that displays the same information. This allows simultaneous data viewing and controller operation without any screen switching interruptions, as the simulated screen and actual controller can be accessed concurrently.
Solution Approach 2:
The system enables continuous operation by allowing the staff to view machine data on the simulated screen while simultaneously controlling the machine controller without interruption. The data extraction and machine control actions can proceed continuously and simultaneously, eliminating the stop-start pattern caused by screen switching.
3Adaptability or versatility
If the non-invasive data-extraction system is used on old machine controllers, then the system can obtain control machine information, but the machine controller cannot be upgraded to a networked device
Solution Approach 1:
The system introduces a simulated operation screen as an intermediary layer between the old non-networked machine controller and the modern networked environment. This intermediary allows the legacy controller to function as if it were networked, enabling data extraction and simulation capabilities without requiring physical upgrades to the original controller hardware or software.
Solution Approach 2:
The system creates a simulated version of the machine controller interface that replicates the functionality and display of the original old controller. This copied interface provides modern data extraction and networking capabilities while maintaining compatibility with the legacy controller, effectively bridging the gap between old hardware and new capabilities.
Data Source
AI summary
A system module applied to the machine controller for simulating a machine operation screen based on a non-invasive data-extraction system, is disclosed. An image capture device of the system module can receive an original operation screen outputted from the machine controller, and transmit the original operation screen to the non-invasive data-extraction system and a high-speed image process unit for extraction of the information shown on the operation screen. The software control system can extract the operational information of the machine controller in real time, to create a machine operation flow for generating a simulated machine operation screen which is then outputted to a screen of the machine controller. As a result, the site working staff can be provided with operational information associated with the machine in real time, for example, the operational information includes currently executed operation screen, position of mouse cursor and pop-up window detection result.