Upon successful system analysis and after collecting all data we’ll start recreating of the control system in place. We will customize your control system with the most powerful solutions. It will be a useful way to utilize them for a rapid troubleshooting and money saving. To begin our design we will need to get all required documentation. It might be application software, HMI screens, electrical schematics, wiring diagrams, and instrumentation list. In addition, we will need any other data before we will start drafting all required modifications. Therefore, we will provide the following solutions to expedite our proprietary Rapid Troubleshooting Programming:
Rapid Troubleshooting Programming
This programming evolves for the past 30+ years while working in different industries and teaching automation personnel. This programming consists of the following main components:
- Each and every part of the control system, all inputs and outputs, sequence of operation, manual and automatic modes, as well as handling and displaying internal and external faults and alarms .
- Incorporate a new hand-held displays based on a smart phone or 10″ tablet-HMI with WiFi.
- An HTML screen will display any and all faults and alarms within the control system in place.
- A WiFi router will communicate to smart phone or tablet-HMI.
All exiting inputs of the control system will be shown in several states, depending on complexity of the system. Those states, their descriptions and locations will represent the following:
- (1) Initial state of the external or internal device
- (2) normal working state of the same device
- (3) alarm state of the same device
- (4) device state one scan prior to the fault.
Please note that the machine operator will see all I/O states displayed side-by-side in different colors. A machine operator will be able to understand what was the root-fault that triggers all other alarms. It will take merely a second to see any new alarm situation on a page with 50 I/Os. Subsequently, by flipping all alarm pages, ones per second, an operator will be capable to identify any original fault within a minute or so, from 3,000 existing I/Os.
A maintenance technician or a machine operator will be able to understand those different colors and make an educated guess of the root-source of one or another fault.
Please note that this troubleshooting technique and programming becomes available only for the past 10-12 years when smart phones and tablets with WiFi became widely available.
How it Works
All alarms and faults will be displayed on one or more alarm screens either on the existing HMI or SCADA monitors or on a smart phone or a tablet.
When a maintenance technician or a machine operator starts diagnose the machine at fault they check alarm and fault screens for any discrepancies in input colors. After successfully installing many of such systems we came to a conclusion that it merely takes about 30 minutes to train maintenance PLC technician and machine operator on how to evaluate fault colors and pinpoint a root-fault of the problem and correct it.