I need to take an process analog input into a PLC and "learn" the waveform for a known good manufactured part. The signal amplitude will vary during the machine cycle. When the machine goes into production mode, I need to compare that real-time signal against the learned curve and alarm if it is plus/minus 5%. Anyone have a suggestion how to accomplish this? This is a job shop so new parts will frequently need to be "leaned."

If I use SCADA historian software, I don't think the response is fast enough, so I'm thinking I must do it in the PLC. Any suggestions?

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What you did not indicate about your production process is whether or not there is a key event that you can trigger the comparison from. Also, is every cycle of the production process expected to be the same (or very closely similar) within some tolerance level? Does the cyle always take the same time?

The key event is when the analog signal has a value above zero, i.e. when a signal is present. Every cycle will be exactly the same which includes the analog input amplitude over time and for duration of the signal and process.

Extra info would be helpful:
- What PLC platform are you using?
- How long would/could a cycle last?
- Does your analog input move in steps or is it gradual?
- How fast of a reaction do you need (Does it need to be instantaneous, or a would comparison to a sample every 5-30s be acceptable)?

I Dont understand the question