Distributed Automation Control for Safety Volume Coordination
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Solution Overview
Problem
Current automation systems face challenges in comprehensive control and analysis due to segmented data communication between devices and controllers, limiting the capability of central servers to improve process effectiveness and efficiency, especially when manual tasks and non-digitized equipment are involved.
Innovation Solution
A distributed automation control system using microcontrollers powered and communicating via Power over Ethernet (PoE) and Ethernet over Power (EoP) networks, allowing for real-time communication and group learning among members, enabling comprehensive control and monitoring without the need for programmable learning controllers, and facilitating the integration of traditionally non-controlled facility components and mobile objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a programmable learning controller (PLC) is used to control automated equipment performing predetermined sequences, then control capability is improved, but device complexity and data segmentation increase, limiting comprehensive process analysis
Solution Approach 1:
The system divides the automation control into distributed microcontrollers embedded in each device, with each microcontroller independently controlling its local device while communicating process data through a network to a central server for comprehensive analysis
Solution Approach 2:
Each device in the system is equipped with a microcontroller that serves multiple functions: local control of the device, generation of process data, and network communication, eliminating the need for separate PLCs and sensors
2Quantity of substance
If data from multiple controllers and sensors are communicated through a network, then data collection is improved, but data integrability and comprehensive process analysis capability deteriorate
Solution Approach 1:
The central server merges data from multiple microcontrollers and facility components into a unified process model, enabling comprehensive analysis of the entire process by integrating otherwise segmented data streams
3Device complexity
If manual tasks and non-digitized equipment are excluded from controller communication, then system simplicity is maintained, but productivity and comprehensive process control deteriorate
Solution Approach 1:
Manual equipment and facility components are equipped with microcontrollers that enable them to self-report their status and performance data to the network, allowing previously non-digitized elements to contribute to comprehensive process control without requiring complex integration systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables dynamic coordination of tasks, reduces variability in processes, and enhances safety by monitoring interactions between members, allowing for preventive actions without physical safety fences, thereby improving process efficiency and flexibility in equipment layout and resource utilization.
Implementation Method 1
microcontrollers powered and communicating via Power over Ethernet (PoE) and Ethernet over Power (EoP) networks
Data Source
AI summary
A distributed automation control system includes a network for connecting members of the system to a central server for communication between the members and the central server. The members can include a device controlled by a microcontroller in communication with the network, a mobile object digitized to communicate with the central server via the network, and a facility component in communication with the central server. A member can be assigned to one or more groups of members for group learning and for generating a group heartbeat. Each member defines a safety volume which is monitored by the central server. When the safety volume of one member overlaps the safety volume of another member, the central server initiates a responsive action which can include ceasing the operation of at least one of the members.