Triggered Data Tagging for Manufacturing Line Fault Diagnosis
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Solution Overview
Problem
Existing systems for diagnosing automation systems are complex, difficult to configure, and challenging to retrofit, especially when dealing with intermittent faults in modern manufacturing environments.
Innovation Solution
A method and system for diagnosing manufacturing lines with automation elements, involving the receipt of operation data, determination of trigger conditions, capture of feedback data, and storage of this data in association with the operation data and trigger conditions, using a processor and data collection devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera systems are connected to PLC controllers with re-programmed trigger signals, then diagnostic capability is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent introduces an intermediary device that sits between the PLC controller and the camera system. This intermediary receives trigger signals from the PLC, processes them, and generates appropriate trigger signals for the camera without requiring direct integration or re-programming of the PLC. This mediator layer simplifies the overall system architecture while maintaining diagnostic capabilities.
Solution Approach 2:
The diagnostic system is segmented into independent functional modules: the existing PLC controller, the intermediary trigger processing device, and the camera system. Each module operates independently with well-defined interfaces, allowing the camera diagnostic functionality to be added without modifying the core PLC control logic, thus reducing system complexity.
2Measurement precision
If camera systems are re-programmed with trigger signals, then diagnostic capability is improved, but ease of operation and ease of repair deteriorate
Solution Approach 1:
The intermediary device serves as a buffer that translates PLC controller signals into camera-specific trigger signals without requiring re-programming of either the PLC or the camera. This maintains the original configuration of both devices while enabling diagnostic functionality.
Solution Approach 2:
The intermediary device creates a copy or replica of the trigger signal functionality specifically for the camera system, rather than modifying the original PLC control logic. This allows diagnostic triggering to be added without changing the operational configuration of the existing automation controller.
3Measurement precision
If comprehensive data is collected for diagnosis, then measurement precision is improved, but loss of time and productivity deteriorate
Solution Approach 1:
The system continuously collects and stores operational data from the manufacturing line in advance, organized by trigger conditions and timestamps. When a fault occurs, the pre-collected data is already available for immediate retrieval and analysis, eliminating the need for time-consuming data collection during downtime.
Solution Approach 2:
The system periodically captures and stores operational data at defined intervals and trigger events, creating a ready archive of manufacturing line status. This periodic data collection ensures that when a fault occurs, the relevant data has already been captured and is immediately accessible for rapid diagnosis.
Data Source
AI summary
The disclosure is directed at a method and system for diagnosing automation elements. The method and system include the determination of a trigger condition or event within operation data received from the automation elements. Based on the trigger condition or event, feed-back data captured by data collection devices is tagged and stored and/or captured and stored for review by an end user. The feed-back data may be stored together with associated operation data to assist in identifying faults, the causes of faults, or the like in the automation elements, in the products produced, or in the manufacturing process or overall manufacturing system.