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Maintenance Inspector

€450,00 EUR
€450,00 EUR
Sale Sold out
Description

Maintenance_FB scales and filters a process value, automatically learns 10 maximum values ​​over tick cycles, calculates an average from them, and monitors deviations during operation with regard to tolerance and time window. A sliding error FIFO (10 slots) and thresholds for warning and error ranges enable robust diagnostics. Latches, plaintext, and timestamps are managed in the diagnostic UDT.

Note: Module for process diagnostics/quality assurance. Not a safety-related function.

How it works
1) Scaling & Filtering
  • Scaling: ValueRaw = ValueRaw_in * Gain + Offset from #P.UDT_ChannelParams .
  • IIR filter: If FilterTime > 0 , then simple 1st order filter with α = 1/8 : yFilt := yFilt + (ValueRaw - yFilt) * 0.125 ; otherwise ValueFiltered = ValueRaw .
  • Metadata: ChannelName and UnitText are taken from the parameters in the diagnosis.
2) Reset
  • Sets learning and error index to 1, empties arrays LearnValues[1..10] / ErrValues[1..10] , clears counters and latches.
  • Diagnostic fields are specifically reset (ASCII text: Reset ), current measured values ​​are retained; LastErrorDT := NowDT .
3) Learning (10 ticks)
  • Max-Sampler: While #Learn is active and at every #Tick -High the maximum of ValueFiltered is collected.
  • Tick ​​falling edge: If NOT Tick AND Tick_old the maximum value is written to LearnValues[LearnIndex] ; LearnIndex is incremented.
  • After 10 entries the mean value is calculated ( MeanValue ), Learned := TRUE , Status: Learning completed .
4) Error detection (online)
  • Deviation counter: If |ValueFiltered - MeanValue| > Tolerance , then TimeOutCnt ++; otherwise set to 0.
  • FIFO update on tick falling edge:
    • ErrValues[ErrIndex] := (TimeOutCnt ≥ ErrorWindow) ; ErrIndex rotates from 1 to 10.
    • ErrCount = Number of TRUE in ErrValues ​​.
    • Error Latch: If ErrCount ≥ ErrorThreshold and not yet latched ⇒ ErrorLatched := TRUE , ErrorActive := TRUE , ErrorCode := 1001 , Status: Error detected , LastErrorDT := NowDT .
5) Auto-reset in warning area
  • Warning condition: ErrCount > 0 and ErrCount < ErrorThreshold .
  • TON WarnResetTime : After expiration, FIFO, counters and latches are reset; Status: Warning area reset .
6) Status maintenance
  • If Learned = FALSE ⇒ Status: Learning active .
  • If ErrorActive = TRUE ⇒ status remains Error detected .
  • Otherwise ⇒ Status: OK .
  • Edge detection: Tick_old := Tick at cycle end.
Technical details
  • Inputs/Signals: #ValueRaw , #Tick , #Reset , #Learn , #NowDT .
  • Parameters ( #P.UDT_ChannelParams ): Name , UnitText , Gain , Offset , FilterTime , Tolerance , ErrorWindow , ErrorThreshold , WarnResetTime .
  • Diagnostic UDT ( #D.KanalDiagnose ): ChannelName , UnitText , ValueRaw , ValueFiltered , MeanValue , Learned , ErrorActive , ErrorCount , ErrorCode , StatusText , LastErrorDT .
  • Internal variables: yFilt , LearnValues[1..10] , ErrValues[1..10] , LearnIndex , ErrIndex , ErrCount , TimeOutCnt , MaxValue , MeanValue , Tick_old , ErrorLatched , sum , warnCond , tonWarnReset .
Diagnosis & plain texts
  • Reset (reset performed)
  • Training active (not yet 10 samples)
  • Training completed (average calculated)
  • Warning area reset (auto-reset)
  • Error detected (Latch active, ErrorCode=1001 )
  • OK (operation without errors)
Possible applications
  • Sensor/channel monitoring with learning-based reference value
  • Detection of creeping drifts via FIFO windows
  • HMI-friendly diagnostics including latch and timestamp
  • Advance warning with automatic reset
compatibility
  • Siemens TIA Portal V16 (S7-1200/1500), SCL
  • Testable with PLCSIM
Scope of delivery
  • SCL block ChannelDiag_LearnAvg_FB according to the above specification
  • Parameterization UDT and diagnostic UDT (field assignments compatible with the code)
  • Quick guide & integration notes
Support
  • Adjusting window size, filter alpha and learning logic
  • Extension to more samples or moving average
  • HMI messages/language switching (ASCII/UTF-8)
  • Trend/CSV logging of learning/online values