The mills of the 21st century are developing at an alarming rate, and how to keep pace with such development has become a huge challenge for the human-operated control panel. The once massive machine monsters are now rapidly being replaced by computer-controlled systems that use large LCD touch-screen displays for human-computer interaction.

One of the key requirements of these new systems is to be able to recover quickly from sudden unexpected power failures. This article will review the advantages of a system using such a touch screen display control panel, discuss the major challenges in the event of a power outage, and finally explain how to use a client/server architecture based on nvSRAM memory and software transaction logs to easily and economically Find a solution.
Plant Control Panel Development
Over the past few decades, factory automation has evolved into the use of large mechanical control panels including switches, buttons, rotary handles, keyboards, meters, and video displays. The more complex the plant, the more complex its control panels and the more control panels required. We can imagine that each time a control panel is added, the difficulty of training and operation will increase, and the design and implementation costs will skyrocket. Moreover, with more machines and equipment, the total reliability will decrease.

Over the past few decades, factory automation has evolved into the use of large mechanical control panels, including switches, buttons, rotary handles, keyboards, meters, and video displays.
Today, touch displays are replacing mechanical control panels, simplifying operations, increasing reliability, and reducing application costs. The functions that were previously required to be realized through the mechanical control panel can now be realized by an embedded digital system and controlled by an operator using a large touch screen display.

With the touch display, the operator does not need to press a real button or turn a mechanical handle. Instead, the operator can do the same by gently pressing a finger on a button or handle icon in the display and performing the same action. Effect. These large-screen control panels are connected to a large number of digital switches, sensors, meters and vision systems. They can easily display more than 100 icons. Each icon can replace the corresponding mechanical parts in the old mechanical panels, and they can also provide more powerful functions. . For example, the operator needs little training, operates completely with familiarity with the original mechanical control panel, and can instantly switch from one display interface to another.
For example, when it is not easy to display all functions on one interface, the operator can set the system and display different control panel â€œinterfacesâ€ on the LCD screen as required. A touch screen display panel can bring up and display a myriad of different "interfaces", so this is especially useful when the factory needs to transfer the control panel from one job task to another with different control screens. Another unique advantage of this "soft-screen" approach is that in a particular control panel, the functional arrangement can be optimized for each operator's situation. For example, a right-handed operator uses a display scheme while the left hand The operating operator uses another layout scheme.
Power Outages: Hidden Enemies <br> Although we are well aware of the technology that integrates touchscreens into modern industrial control environments, it still has an "Achilles' heel" - an accidental power outage. The mechanical control panel can ensure the key status information is not lost through the static nature of the mechanical components, but the embedded system using the touch screen control panel is not the same, and it needs to have a very reliable and fail-safe response to the power failure event to ensure The factory's status information is safely stored and returned to this state after power is restored.
Failure to properly restart and restore intelligent panel solutions will make the factory's shutdown and resumption of work an absolute nightmare, resulting in heavy downtime, wasted materials, and even physical injury to workers. The factory owner will not allow the replacement of a reliable mechanical panel unless the new digital LCD touch screen can accurately replace it 100%. Mechanical panels can often be restored after a power failure, so the latest embedded control panels with touch screens must do the same.
Mechanical Control Panel Overview <br> The factory's main server is the heart of a mechanical control panel system that coordinates all monitoring and data acquisition sensors and manages all running control points in the plant. By controlling the plant's networked I/O board, the host server coordinates all monitoring and data acquisition sensors - such as sensors to measure voltage, current, water pressure, weight, airflow, read and write barcodes, and manage all operations in the plant Control points in the system, such as starters, solenoids, motors, fans, scrubbers, belts, and heaters. Although a small percentage of the plants have achieved 100% automation, and the rate of such plants is still increasing, most factories still require human operators to monitor all aspects of the plant's operation.

To help these workers, human-operated control panels are distributed throughout the factory and connected to the main server via a network bus such as CAN, ProfiBus or ModBus. When using a mechanical control panel, the operator uses buttons, selector switches, variable resistors, etc. to make adjustments. These settings are then digitized and transmitted to the main server via the network bus.
Similarly, sensor data is also sent from the I/O board to the control panel via the network bus and displayed to the operator via analog meters, digital readers, and LEDs. In the event of a power outage, the main server will continue to receive power from a UPS power supply and save hundreds of sets of settings in the factory so that when the plant resumes power, it can quickly and sequentially restore operations.

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