Method and apparatus for analyzing machine control systems
First Claim
1. A diagnostic system for analyzing conditions of critical points in a corrugator and for generating an operator message based on the conditions, the diagnostic system comprising:
- sensing means for sensing the conditions of the critical points in the corrugator and for generating critical point signals representative of the conditions of the critical points;
isolator means having an input port and an output port for receiving the critical point signals generated by the sensing means at the input port, and for generating logic signals representative of the critical point signals at the output port, the output port being isolated from the input port by the isolator means; and
controller means for receiving the logic signals generated by the isolator means and for generating an operator message based on the logic signals wherein the controller means includes;
first fault detection means for prioritizing faults to detect a first fault representing the condition of the particular critical point which caused the corrugator to stop running; and
current condition detection means for periodically detecting a current condition representing whether the corrugator is in a ready to run state or in a most critical fault condition state wherein a most critical fault condition is identified which must be remedied to start the corrugator.
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Abstract
A diagnostic system analyzes conditions of critical points in a production line. The diagnostic system generates an operator message based on the conditions it analyzes. A sensor senses the conditions of the critical points in the production line and generates critical point signals representative of the conditions of the critical points. An isolator receives the critical point signals and generates logic signals representative of the critical point signals. The isolator isolates the logic signals from the critical point signals. A controller receives the logic signals and generates an operator message based on the logic signals.
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Citations
73 Claims
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1. A diagnostic system for analyzing conditions of critical points in a corrugator and for generating an operator message based on the conditions, the diagnostic system comprising:
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sensing means for sensing the conditions of the critical points in the corrugator and for generating critical point signals representative of the conditions of the critical points; isolator means having an input port and an output port for receiving the critical point signals generated by the sensing means at the input port, and for generating logic signals representative of the critical point signals at the output port, the output port being isolated from the input port by the isolator means; and controller means for receiving the logic signals generated by the isolator means and for generating an operator message based on the logic signals wherein the controller means includes; first fault detection means for prioritizing faults to detect a first fault representing the condition of the particular critical point which caused the corrugator to stop running; and current condition detection means for periodically detecting a current condition representing whether the corrugator is in a ready to run state or in a most critical fault condition state wherein a most critical fault condition is identified which must be remedied to start the corrugator. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45)
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46. The diagnostic system for analyzing conditions of critical points in a production line and for generating an operator message based on the conditions, the diagnostic system comprising;
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sensing means for sensing the conditions of the critical points in the production line and for generating critical point signals representative of the conditions of the critical points; and controller means for receiving the critical point signals generated by the sensing signals and for generating an operator message based on the critical point signals wherein the controller means includes; first fault detection means for prioritizing faults to detect a first fault representing the condition of the particular critical point which caused the production line to stop running; and subsequent fault detection means for detecting a subsequent fault representing the condition of a critical point which has prevented the production line from being restarted after the first fault caused the production line to stop running, and after the production line has been returned to a ready to run state, where the subsequent fault arises after the first fault. - View Dependent Claims (47, 48, 49, 50, 51, 52)
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53. A method for analyzing critical points in a production line comprising the steps of:
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prioritizing faults to identify an initial fault condition, based on state of the critical points, which caused the production line to stop running; detecting a current condition of the production line representing the state of a most critical point where the current condition is keeping the production line from being restarted; and generating an operator message based on the initial fault condition and the current condition. - View Dependent Claims (54, 55, 56, 57, 58, 59, 60, 61)
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62. A method for analyzing critical points in a production line where critical points change state when a fault condition occurs stopping the production line, the method comprising the steps of:
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storing state changes of the critical points in fault latches; determining that the production line has stopped based on a production line condition signal; sampling the fault latches and prioritizing fault conditions to determine an initial fault condition causing the production line to stop; sampling current states of the critical points after sampling the fault latches; determining a most critical current condition of a critical point in keeping the production line from starting; and generating an operator message indicating the critical point causing the initial fault and indicating the most critical current condition.
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63. An apparatus for analyzing critical points in a production line comprising:
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identifying means for prioritizing fault conditions to identify an initial fault condition, based on a state of the critical points, the initial fault condition causing the production line to stop running; detecting means for detecting a current condition of the production line representing the states of a most critical point keeping the production line from being restarted; and generating means for generating an operator message based on the initial fault and the current condition. - View Dependent Claims (64, 65)
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- 66. The apparatus of claim wherein the operator message is updated each time the detecting means detects the current condition.
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72. An apparatus for analyzing critical points in a production line where the critical points change state when a fault condition occurs stopping the production line, the apparatus comprising:
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storing means for storing state changes of the critical points, the state changes being stored in fault latches; determining means for determining that the production line has stopped based on a production line condition signal; sampling means for sampling the fault latches and prioritizing fault conditions to determine an initial fault condition which caused the production line to stop; current sampling means for sampling current states of the critical points after sampling the fault latches; critical determining means for determining a most critical current condition of a critical point in keeping the production line from starting; and generating means for generating an operator message indicating the critical point causing an initial fault and indicating the most critical current condition. - View Dependent Claims (73)
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Specification