Abstract: Textual fault messages in PLC-based manufacturing systems are supplemented by automatically displayed sets of information that allow an operator to quickly identify, recognize and visualize components responsible for producing faults. Visual display of stored computer generated images showing system components and tooling allow the operator to visually pinpoint the exact component responsible for the fault, and its location within the manufacturing system. Stored information associated with the component producing the fault, such as installation date, vendor sources, replacement part inventory, programming logic and editing software, is also automatically recalled and displayed along with the fault message to aid fault diagnosis and correction.

Abstract: A method is provided of embedding tooling control data within a mechanical fixture design to enable programmable logic control verification simulation. The method includes the steps of constructing at least one of a mechanical fixture design, a workcell design, and a controls design. The method also includes the steps of executing a virtual programmable logic control (VPLC) simulation with a VPLC verification simulator to verify the at least one of the mechanical fixture design, the workcell design, and the controls design.

Abstract: A method is provided of application protocol monitoring for a manufacturing line including the steps of constructing a manufacturing line model for the manufacturing line, utilizing logic for a programmable logic controller (PLC), executing a control logic simulation of the PLC logic to validate the PLC logic against the manufacturing line model, creating a database containing validated I/O tag expected intents confirmed from the control logic simulation, and applying the application protocol monitoring device to a network for the manufacturing line to monitor traffic across the network and continuously compare the I/O tag status across the network to the database of validated I/O tag expected intents.

Abstract: A method is provided of application protocol monitoring for a manufacturing line including the steps of constructing a manufacturing line model for the manufacturing line, utilizing logic for a programmable logic controller (PLC), executing a control logic simulation of the PLC logic to validate the PLC logic against the manufacturing line model, creating a database containing validated I/O tag expected intents confirmed from the control logic simulation, and applying the application protocol monitoring device to a network for the manufacturing line to monitor traffic across the network and continuously compare the I/O tag status across the network to the database of validated I/O tag expected intents.

Abstract: Textual fault messages in PLC-based manufacturing systems are supplemented by automatically displayed sets of information that allow an operator to quickly identify, recognize and visualize components responsible for producing faults. Visual display of stored computer generated images showing system components and tooling allow the operator to visually pinpoint the exact component responsible for the fault, and its location within the manufacturing system. Stored information associated with the component producing the fault, such as installation date, vendor sources, replacement part inventory, programming logic and editing software, is also automatically recalled and displayed along with the fault message to aid fault diagnosis and correction.

Abstract: A method is provided of embedding tooling control data within a mechanical fixture design to enable programmable logic control verification simulation. The method includes the steps of constructing at least one of a mechanical fixture design, a workcell design, and a controls design. The method also includes the steps of executing a virtual programmable logic control (VPLC) simulation with a VPLC verification simulator to verify the at least one of the mechanical fixture design, the workcell design, and the controls design.