PLC Display Module: Configuration of Status Monitoring Panel for Clear Device Operation!

Introduction

“Master, the production line No. 3 has alarmed again! But this time all the fault lights are on, and I can’t tell where the problem is!” Is this a complaint you often hear in the workshop? Today, I want to share a solution that makes the device status “clear at a glance” — the configuration of the PLC display module’s status monitoring panel. By reasonable configuration, it can not only reduce fault troubleshooting time by 70% but also allow operators to have a clear understanding of the device’s operating status! Want to know how to achieve this? Let’s explore together!

Why Do We Need Professional Display Modules?

Imagine driving a car where the dashboard only has a red warning light, but it doesn’t tell you whether you’re out of fuel, the engine is overheating, or the tires are under pressure — this is the current state of many factory equipment monitoring! Traditional PLC indicator lights and simple displays have three major pain points:

1. Fragmented Information: Fault codes are scattered across different modules, requiring manual reference to the manual for interpretation.

2. Delayed Response: By the time the alarm light comes on, it may have already caused product scrap.

3. Experience-Dependent Operation: Only veteran employees can determine the type of fault from the flashing frequency.

Professional display modules are like equipping devices with a “smart cockpit”:

• Blue area displays normal operating parameters (temperature/pressure/speed)

• Red area highlights abnormal indicators

• Yellow area provides early warning of potential risks

Analysis of Mainstream Display Module Types

1. Text Display (TD Series)

Applicable Scenarios: Simple equipment status monitoring

Advantages:

• Low cost (about 1/3 the price of a regular HMI)

• Supports custom alarm messages (e.g., “Hydraulic pump A pressure insufficient”)

Case Study: After adding the TD400C to a packaging machine, operators can directly see the clear prompt of “Sealing temperature too low”, reducing fault response time from 15 minutes to 2 minutes!

2. Touch Screen HMI (KTP/TP Series)

Applicable Scenarios: Monitoring complex process flows

Key Features:

• Dynamic Flow Chart displays real-time device operating status

• Trend Chart records changes in key parameters (e.g., 24-hour temperature curve)

• Recipe Call function (switch production models with a click on the screen)

Actual Effect in an Automotive Welding Workshop:

Through the KTP1200 screen’s multi-level menu design, even novice operators can find:

1. Current welding parameters

1. Historical fault records

1. Device maintenance countdown

3. Industrial Tablet PC

Advanced Features:

• Monitor multiple PLCs simultaneously via OPC UA protocol

• Remote access feature (engineers can diagnose faults from the office)

• Video monitoring integration (e.g., observing injection molding machine mold status)

Golden Configuration Rules for Status Monitoring Panels

▶ First Visual Layer: Key KPI Dashboard

• Use analog gauge dials to display core parameters (speed/pressure)

• Digital Labels must include:

• Current value (blue)

• Set value (black)

• Deviation percentage (red highlights for out-of-range situations)

▶ Second Logical Layer: Device Status Matrix

| Icon | Meaning | Trigger Condition |

|——-|——-|——-|

| ![Running] | Motor running | Speed>100rpm |

| ![Alarm] | Temperature abnormal | Actual value>set value 15% |

| ![Maintenance] | Needs lubrication | Running hours>500 |

▶ Third Detail Layer: Diagnostic Information Tree

1. Main Power Status

   ├─ Voltage: 380V (Normal)

   └─ Current: 45A (Warning: +8% compared to baseline)

2. Pneumatic System

   ├─ Pressure: 0.6MPa

   └─ Filter Remaining Life: 120h

Pitfall Guide: 5 Common Mistakes Made by Beginners

1. Information Overload: Piling all 200 variables on the homepage → Should follow the **”3-second rule”** (operators must find key information within 3 seconds)

2. Color Misuse: Using 7 colors to distinguish states → In fact, only need:

• Red: Fault/Shutdown

• Yellow: Warning/Standby

• Green: Normal operation

Ignoring Night Shift Needs: Not configuring backlight auto-adjustment, leading to reflections that make it hard to see at night

Lack of Historical Traceability: Not configuring data recording function, making it impossible to find trend data during fault analysis

Touch Targets Too Small: Button size <15mm², impossible to operate while wearing gloves

Practical Case: A Glamorous Transformation in an Injection Molding Workshop

Comparison before and after the renovation of an appliance parts factory:

| Indicator | Before Renovation | After Renovation |

|——-|——-|——-|

| Fault Response Time | 25 minutes | 4 minutes |

| Misoperation Frequency | 3-5 times per week | <1 time per month |

| OEE Equipment Overall Efficiency | 68% | 89% |

Key Renovation Points:

1. Create a mold life counter on the KTP700 screen

2. Set up automatically changing colors for the hydraulic pressure indicator bar

3. Add audible and visual alarm for emergency stop button status indication

Interactive Discussion

1. What is the most user-friendly display module you have used? What is its killer feature?

2. When configuring the monitoring interface, how do you balance completeness of information and interface simplicity?

3. Have you ever encountered misoperation accidents due to display issues? How did you resolve it later?

Conclusion

A good status monitoring panel is like equipping devices with “talking eyes” — it not only reflects the health status of the equipment in real-time but also transforms obscure PLC data into intuitive production language. Remember:Behind the “clear at a glance” is a carefully designed visualization logic!

Next time you walk through the workshop and see operators frowning at the screen, ask yourself:“Does this interface really tell the story of the equipment clearly?” Feel free to share your visualization design insights in the comments!

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