Find a Unit, Part, or Sensor
Search by PLC, area, station, tool, sensor code, IEC designation, tag, or fault description.
Units Overview
Current fault state grouped by production unit.
Live Feed
Active faults, most recent first.
Volvo 2V06 — Real Wall Line
PLC preview page showing live faults for one production line, cell statuses, last event, and direct access to the relevant 3D component preview and guided fix workflow.
Connected • Last event: 2026/01/08 10:53:14 • Scan: 1s • Safety: Active
Live Faults from This Unit
Each fault log is linked to unit, part/sensor metadata, and a physical location preview.
3D Component Preview
CAD/model reference for the selected device, sensor, or station.
Fault in Part — V1 K18 WR1UQ51 BG31
Highlighted component: part-present sensor near fixture bottom-left area.
Fault Present Part — WR1UQ51BG31
Fault status: open • Severity: fault • Seen 1456 times • Started: 2026/01/08 10:53:14
AI Summary
The PLC expected part presence at V1 K18 tool WR1UQ51, but BG31 did not confirm the part. Verify HMI tool screen, part seating, sensor detection, cable, and I/O block before escalating PLC logic.
- HMI area: =2V06+V1UC32.
- Tool: V1WR1UQ51.
- Sensor: BG31.
Likely Root Cause
Most likely: part not seated properly, dirty/misaligned BG31 sensor, damaged sensor, loose M12 cable, incorrect I/O block port, or drawing revision mismatch.
Confidence: 87% based on similar solved cases and technician notes.
Step That Usually Solves This
Step 5: If the part is seated correctly, adjust the sensor to detect the part more reliably.
Historically effective for presence faults and nuisance triggers.
Guided Steps
The system shows one step at a time. The full procedure is shown as bulletpoints only for context.
AI can reorder the step sequence based on the current fault pattern, historical solved cases, technician notes, repeat count, safety level, and which step usually solved similar issues. This means Step 1 is the most likely safe starting point for this specific issue, not necessarily the original manual order.
AI-Ranked Procedure Order
Technician Notes & Evidence
Stored with the resolution case and reused by AI for future recommendations.
3D Component Context
Selected fault location and maintenance access points.
Highlighted Sensor Location
Use this visual to locate the exact component before physical inspection.
Fault History
Complete record of historical errors, statuses, solution steps, technician notes, attachments, and AI learning output.
Audit Log
Chronological record of user sign-ins, sign-outs, and resolved faults. Click a resolved entry to see the solution step that was selected and the technician note that was written.
10:40:12
10:38:50 ▾
10:25:31 ▾
10:05:08
08:05:44
07:52:19 ▾
07:30:02
Export Historical Data
Generate Excel, CSV, or PDF reports for maintenance reviews, recurring faults, downtime, and resolved cases.
Data Preview
| Date | Time | Device | Code | Severity | Description | Status | Solution Step |
|---|---|---|---|---|---|---|---|
| 3/5/2024 | 07:34:57 | BodySides | 10000 | Fault | DAS - Not receiving plant floor data | Resolved | Step 2 |
| 1/8/2026 | 10:53:14 | 2V06 V1 K18 | BG31 | Fault | Part expected but not detected | Resolved | Step 5 |
| 3/5/2024 | 08:44:51 | BodySides | 22 | Warning | S01AR02 drop-off 1 over cycle time | Resolved | Step 5 |
| 3/5/2024 | 08:49:43 | BodySides | 971 | Warning | S01ATT operator load overcycle | Open | - |
Areas & Stations
Define production areas and manage the stations inside each area. Units are later assigned to a specific area and station, so the hierarchy stays clean and searchable.
Existing Areas
Each area can contain multiple stations. Use stations to locate units, tools, robots, safety zones, and utility systems accurately.
| Area Code / Name | Related Central Machine | Description | Stations Inside Area | Units Assigned | Safety Classification | Status | Actions |
|---|---|---|---|---|---|---|---|
| V1 — Rear Wall Area 1 |
2V06 Central Log Machine | Contains K10/K12 operator safe zones and K18 WR1UQ51 fixture station. | K10 K12 K18 S010 | 7 | Safety Critical | Active | |
| V2 — Robot Area |
2V06 Central Log Machine | Contains K30 AR41 robot station and tool-change/end-effector I/O locations. | K30 S030 S035 | 5 | Robot Cell | Active | |
| KH3 — Water Utility Area |
2V06 Central Log Machine | Water filter, flow switch, headers, valves, and cooling lines. | KH3-IN KH3-OUT HEADER-A | 2 | Utility | Active |
When creating a unit, the admin first selects the area. The station dropdown then shows only stations related to that area, preventing units from being assigned to the wrong section.
Units
Manage unit/cell records and assign each unit to a PLC, line area, HMI, safety zone, and CAD model.
Existing Units
Units are children of PLCs and parents of unit parts, sensors, debug steps, and 3D model mapping.
| Unit / Cell | Related Central Machine | Area | Station | HMI | Unit Type | Parts/Sensors | Criticality | Status | Actions |
|---|---|---|---|---|---|---|---|---|---|
| V1 K18 — WR1UQ51 Tool | 2V06 Central Log Machine | V1 — Rear Wall Area 1 | K18 — WR1UQ51 | =2V06+V1UC32 | Fixture / Tool | 38 | High | Active | |
| V1 K10/K12 Operator Safe Zones | 2V06 Central Log Machine | V1 — Rear Wall Area 1 | K10 / K12 Operator Safe Zones | =2V06+V1UC32 | Safety Zone | 16 | Safety | Active | |
| V2 K30 — AR41 Robot | 2V06 Central Log Machine | V2 — Robot Area | K30 — AR41 | =2V06+V2UC32 | Fanuc Robot Cell | 42 | High | Active | |
| KH3 Water Distribution | 2V06 Central Log Machine | KH3 — Water Utility Area | KH3-IN / HEADER-A | Utility HMI | Utility System | 33 | Medium | Active |
When adding a unit, the admin selects its PLC first. The form then links HMI screen, CAD model, electrical/pneumatic/water drawings, station identifiers, safety classification, and related fault tags.
Unit Parts & Sensors
Manage components, sensors, safety devices, I/O points, cables, drawings, and 3D references used inside each unit.
Existing Parts & Sensors
Parts can be mechanical, electrical, pneumatic, water/cooling, robot, safety, I/O module, or instrument devices.
| Tag / Designation | Part / Sensor Name | Used In Unit | Type | I/O / Port | Drawing / CAD | Failure Mode | Status | Actions |
|---|---|---|---|---|---|---|---|---|
| WR1UQ51BG31 | Part-present sensor BG31 | V1 K18 — WR1UQ51 Tool | Sensor | DI / M12 sensor input | EFS sensor page + 3D fixture | Part not detected / Output BG alarm | Verify Drawing | |
| V1FQ1 S010-LT1 | Operator side light curtain | V1 K10/K12 Operator Safe Zones | Safety | Safety DI | EFS V1FQ1 pages | Obstruction / misalignment / safety stop | Active | |
| V1FQ1 Scanner 1 | Laser area scanner | V1 K10/K12 Operator Safe Zones | Safety | Safety DI / scanner config | EFS V1FQ1 scanner pages | Zone intrusion / dust / wrong field config | Active | |
| V2AR41UQ41 KF1 | Robot end-effector I/O module | V2 K30 — AR41 Robot | I/O Module | Profinet / device bus | EFS + MFS pneumatic references | No communication / bus unit error | Active | |
| =KH3-BF2 | Main water flow switch | KH3 Water Distribution | Instrument | PNP N.O. M12 | Water page 3 / parts list | No flow / sensor fault | Active |
CAD Models
Upload, preview, edit, and delete CAD/3D models used to visually guide technicians to the exact unit, part, sensor, robot, safety device, or utility component.
CAD Model Library
Models can be linked to PLCs, units, parts, sensors, debug steps, and AI fault suggestions. Recommended web-preview formats are GLB/GLTF; engineering source files can be STEP, SLDASM, SLDPRT, IPT, IAM, OBJ, or FBX.
| Model Name | Related Central Machine | Related Unit | Mapped Parts / Sensors | Format | Version | Preview | Status | Actions |
|---|---|---|---|---|---|---|---|---|
| V1WR1UQ51 Fixture Assembly |
2V06 Central Log Machine | V1 K18 — WR1UQ51 Tool | BG31, BG27, BG28, clamps UQ1-UQ6 | GLB + STEP | Rev 2026.01 | Published | ||
| BG31 Sensor Marker |
2V06 Central Log Machine | V1 K18 — WR1UQ51 Tool | WR1UQ51BG31 | GLTF Marker | Rev 1.0 | Needs Review | ||
| V1 K10/K12 Safety Zone Layout |
2V06 Central Log Machine | V1 K10/K12 Operator Safe Zones | S010-LT1, S010-LT2, Scanner 1-4, gate switch | GLB + PDF overlay | Rev 2025.11 | Published | ||
| AR41 Robot End Effector |
2V06 Central Log Machine | V2 K30 — AR41 Robot | V2AR41UQ41, V2AR41UQ42, I/O module KF1 | GLB + STEP | Rev 2026.02 | Published | ||
| KH3 Water Distribution Preview |
2V06 Central Log Machine | KH3 Water Distribution | =KH3-BF2, HQ1, FL1, KH valves | SVG + GLB | Rev 2022.09 | Published |
When uploading a model, the admin should choose the related PLC, unit, part/sensor tags, CAD format, revision, and whether the file is a full unit model, component-only model, clickable marker layer, or drawing overlay. This allows the guided-fix page to open the exact model position for the current fault.
Unit-Specific Debug Steps
Admin can view, add, edit, or delete troubleshooting procedures linked to unit, sensor, fault family, trigger pattern, and CAD mapping.
Debug Step Library
These records drive the guided technician workflow and AI recommendation ranking.
| Fault Family | Unit Zone | Trigger Pattern | Steps | CAD Mapping | Learning Enabled | Related Sensors | Actions |
|---|---|---|---|---|---|---|---|
| Part Presence Fault | V1 K18 — WR1UQ51 Tool | *BG*_Fault, *Output BG alarm | 9 | Fixture + BG sensor marker | Yes | WR1UQ51BG31, BG27, BG28 | |
| Operator Safe Area Intrusion | V1 K10 / K12 Safe Zones | *Intrusion, *Open Gates to Reset | 8 light curtain + 7 scanner | Safety zone, light curtain, scanner | Yes | S010-LT1, S010-LT2, scanners | |
| Robot I/O Communication Fault | V2 K30 — AR41 Robot | *AR41*, *I/O device*, *Bus unit* | 10 | Robot controller + end effector | Yes | V2AR41UQ41, V2AR41UQ42 | |
| Utility Flow Fault | KH3 Water Distribution | *BF2*, *flow switch*, *water* | 6 | Water schematic + flow switch | Yes | =KH3-BF2, HQ1, FL1 |
Each debug-step set should store safety requirements, lockout/tagout rule, prerequisite skill, required tools, expected PLC/HMI feedback, normal signal state, escalation owner, estimated resolution time, and whether image evidence is mandatory.
AI Configuration
Configure local AI paths, server, port, system prompt, uploaded instruction documents, retrieval rules, and offline model behavior.
Local AI Server
Used for secure on-prem fault explanation, root cause suggestions, and debug-step ranking.
Industrial AI Prompt
Prompt should always prioritize safety, confirmed facts, and ordered next actions.
Uploaded Instructions & Knowledge Base
Documents used for retrieval: debug guides, IEC designation tables, electrical prints, pneumatic prints, water schematics, CAD references, and solved-case history.
| Document | Type | Linked Scope | Version | Indexed | Usage | Actions |
|---|---|---|---|---|---|---|
| Volvo_Debug_Guide.docx | Debug procedure | 2V06 / faults 1-3 | 2026 | Yes | AI summaries + guided steps | |
| Volvo_IEC81346-2 designation.xlsx | Designation dictionary | Plant / Area / Function / Component | Current | Yes | Tag decoding | |
| =2V06&EFS_EL.pdf | Electrical prints | 2V06 EFS electrical | 1503 pages | Yes | Sensor/I/O/drawing lookup | |
| =2V06&MFS-PNEU.pdf | Pneumatic prints | 2V06 robot cell pneumatics | 247 pages | Yes | Clamps, air, valves | |
| =2V06&MFS-WATER.pdf | Water schematic | KH3 cooling/water | 7 pages | Yes | Flow switch and water faults |
AI Continuous Learning Loop
The system improves recommendations from historical cases, technician notes, uploaded images, marked solution steps, and fault recurrence data.
Read PLC fault, tag, severity, count, cell, and timestamp.
Find similar fault codes, devices, unit zones, and solved cases.
Show ordered steps, root cause, and 3D component preview.
Save selected solution step, notes, images, and time-to-resolve.
Promote steps that solved similar faults and demote unsuccessful paths.
Recommendation Ranking Example
For WR1UQ51BG31 recurring part presence fault.
| Rank | Suggested Action | Historical Success | Confidence |
|---|---|---|---|
| 1 | Confirm part is present and seated properly in fixture | 11 / 18 | 89% |
| 2 | Adjust sensor to detect part more reliably | 9 / 18 | 87% |
| 3 | Inspect sensor condition and replace if damaged | 6 / 18 | 74% |
| 4 | Inspect I/O cable and M12 connection | 5 / 18 | 71% |
| 5 | Have PLC asset check logic and hardware configuration | 2 / 18 | 48% |
Learning Rules
Logical safeguards for industrial reliability.
- AI suggestions are advisory; technician confirmation is required before closing a fault.
- Solution ranking is based on same unit zone, tag similarity, code, severity, and confirmed resolution.
- Uploaded images are linked to the case as evidence and can be reviewed by maintenance leads.
- Unsafe actions are never suggested before lockout/tagout and basic electrical/safety checks.
- New central machines, units, sensors, CAD mappings, and debug steps are governed from the administration tabs.
Central Machines
Manage every central machine/log source, its connection, log intake rules, plant area, security zone, and unit mapping. The central machine is connected to PLCs, but Alfa-Debug reads fault logs from the central machine instead of connecting directly to PLC data.
Existing Central Machines
Each row can be viewed, edited, or deleted. Central machines are the parent log sources connected to PLCs; Alfa-Debug reads their logs without requiring direct PLC data access.
| Central Machine Name | Line / Plant | Log Source Type | IP / Endpoint | Log Poll / Watch | Units | Status | Security Zone | Actions |
|---|---|---|---|---|---|---|---|---|
| 2V06 Central Log Machine | Volvo Rear Wall / V06 | Central log collector | 192.168.10.24 | Live watch | 6 | Online | Cell LAN / Level 2 | |
| 2V10 Central Log Machine | Volvo BodySides | Central alarm export | 192.168.10.31 | Live watch | 4 | Online | Cell LAN / Level 2 | |
| Engine Box Central Machine | Engine_Box | Log API / file watch | opc.tcp://10.10.2.14:4840 | 5s poll | 3 | Maintenance | Maintenance VLAN |
Settings & Program Users
Manage users, roles, permissions, tab access, audit trails, and operational security.
Users & Roles
Technicians should access operations. Admins can access everything. Maintenance leads can approve resolution cases and edit debug steps.
| User | Role | Allowed Tabs | Unit Scope | Can Close Faults | Last Active | Status | Actions |
|---|---|---|---|---|---|---|---|
| maintenance.admin | Administrator | All tabs | All PLCs | Yes | Today 10:24 | Active | |
| line.tech01 | Technician | Overview, Unit Preview, Guided Fix, History | 2V06, 2V10 | Yes | Today 09:56 | Active | |
| lead.maintenance | Maintenance Lead | Operations, History, Debug Steps, Learning | BodySides + 2V06 | Approve | Yesterday 16:18 | Active |
Role Permission Matrix
Recommended access model for industrial plants.
| Role | Operations | History | Export | Central Machines / Areas / Units / Sensors | CAD Models | Debug Steps | AI Config | Users |
|---|---|---|---|---|---|---|---|---|
| Technician | View + operate | View | No | No | View only | View only | No | No |
| Maintenance Lead | View + operate + approve | View | Yes | View only | View + annotate | Edit | No | No |
| Engineer | View + operate | View | Yes | Edit | Edit | Edit | View | No |
| Administrator | Full | Full | Full | Full | Full | Full | Full | Full |
| Viewer / Auditor | View only | View only | Yes | No | View only | No | No | No |