Asynchronous Machine Control via Virtual Master Segmentation
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Solution Overview
Problem
Modern industrial automation systems often fail to fully utilize a machine's operational capabilities due to synchronous control methods that coordinate all machine axes with a virtual master, limiting flexibility and efficiency.
Innovation Solution
The method involves asynchronously controlling a machine by generating a system master count that varies over operational cycles, allowing sub-system master counts to be based on this count, enabling independent operation of machine components and modules, and allowing for controlled stopping and reconfiguration of sub-systems without shutting down the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If synchronous control is used to coordinate all machine axes with a virtual master, then coordination and synchronization are improved, but operational flexibility and efficiency deteriorate
Solution Approach 1:
The control system is segmented into a master control unit and multiple independent slave control units. Each slave axis has its own controller that can operate independently while receiving synchronization signals from the master. This segmentation allows individual axes to be controlled asynchronously rather than being forced into synchronous operation, thereby improving operational flexibility while maintaining coordination where needed.
Solution Approach 2:
The system dynamically switches between synchronous and asynchronous control modes for different slave axes. The master controller can send synchronization signals when coordination is required, while allowing slave axes to operate independently when flexibility is needed. This dynamic adaptability resolves the contradiction by making the control mode flexible rather than fixed.
2Stability of the object's composition
If all machine axes are coordinated with the virtual master all of the time, then synchronization is improved, but productivity and efficiency deteriorate
Solution Approach 1:
Instead of applying synchronous control to all axes at all times (excessive action), the system applies synchronization only to the specific slave axes that require it at any given moment (partial action). The master controller selectively sends synchronization signals only when needed, allowing other axes to operate independently and improve overall productivity.
Solution Approach 2:
The control system changes the synchronization parameter dynamically. Each slave axis can switch between synchronized mode (when coordination is needed) and asynchronous independent mode (when productivity is prioritized). This parameter change allows the system to optimize for either synchronization or efficiency depending on the operational requirements.
3Reliability
If a fault occurs in one module, then system reliability is improved through fault detection, but overall system operation deteriorates due to mandatory shutdown
Solution Approach 1:
The system is segmented into independent modular units, each with its own controller. When a fault is detected in one module, only that specific module is affected while other modules continue to operate independently. This segmentation prevents cascading failures and allows continuous operation of healthy modules, maintaining productivity while ensuring fault detection and isolation.
Solution Approach 2:
The master controller acts as an intermediary that coordinates between slave modules but does not create a single point of failure. When a fault occurs in one slave module, the master controller isolates the fault to that module while allowing other slave modules to continue operating asynchronously, thus maintaining overall system productivity while ensuring reliable fault detection and containment.
Data Source
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AI summary
A method of machine control can include providing at least a system master signal, selectively synchronizing at least sub-system master signal to the system master signal based on the value of the system master signal, and carrying out at least one operation based on the value of the other master signal. For example, a machine controller may provide a system virtual master signal and synchronize one or more module virtual master signals to the system virtual master based on the system virtual master count value. One or more components of the module may operate based on the count value of the module virtual master signal. The use of an asynchronous control method may advantageously increase the flexibility of the machine. Because the operation of the components of the machine may depend on respective virtual master signals, a machine using asynchronous control methods may advantageously continue operating one component or module in the event of a fault involving other components. Additionally, component operation can be redefined while other components of the machine continue to run.