Buffer Synchronization for Asynchronous Automation Networks
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Solution Overview
Problem
Existing asynchronous network segments in automation systems cannot guarantee synchronized data transmission for actuators, leading to potential offsets during coordinated actions, as there is no assurance that all devices receive context-correct setpoints at the same time.
Innovation Solution
A method involving an intermediate storage device, or 'buffer', is introduced between the asynchronously operating network segment and the higher-level control unit to decouple and synchronize data transmission, ensuring that control data are processed in the correct context and order, even over asynchronous connections, by using a 'store and forward' system that adjusts its transmission clock based on buffer fill levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If asynchronous data transmission is used to connect control units and actuators, then network flexibility and ease of integration are improved, but synchronous control capability and coordination precision deteriorate
Solution Approach 1:
A buffer device is introduced as an intermediary component between the asynchronous network segment and the synchronous actuator network. The buffer receives control data asynchronously from the control unit, stores it temporarily, and then transmits it synchronously to the actuators at precisely timed intervals, thereby mediating between the two different transmission modes and enabling both flexibility and precision
Solution Approach 2:
The network transmission path is segmented into two distinct sections: an asynchronous segment for flexible data collection and transmission to the buffer, and a synchronous segment from the buffer to the actuators for precise coordinated control. This segmentation allows each segment to operate optimally in its own transmission mode while working together as a unified system
2Adaptability or versatility
If asynchronous transmission is used, then device compatibility and integration ease are improved, but data transmission reliability and timing accuracy deteriorate
Solution Approach 1:
The buffer performs preliminary actions by pre-receiving and storing control data before the actuators need it. Data is accumulated in the buffer in advance during asynchronous transmission, then released in a synchronized manner at the precise moment needed by the actuators, ensuring timing accuracy is maintained despite asynchronous input
3Adaptability or versatility
If synchronous control is implemented over asynchronous networks, then coordinated multi-axis movement capability is improved, but system complexity and buffer management requirements increase
Solution Approach 1:
The buffer is designed to autonomously manage its own operations including automatic data reception, timing-based transmission, and overflow protection. It self-regulates the synchronization process without requiring complex external control logic, thereby enabling coordinated multi-axis movement while keeping the overall system complexity manageable
Data Source
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AI summary
The method involves outputting control data i.e. individual messages (T1-T4), for a subordinate network subscriber (20-50) by a master control unit (10) i.e. electrical control unit. The control data is transmitted to a temporary storage unit via an asynchronously operating network segment (101) and temporarily stored. The control data read from the storage unit is transmitted to the subordinate network subscriber via a synchronous network segment (201) operating with a transmission clock pulse. The clock pulse is changed based on amount of the data temporarily stored in the storage unit. An independent claim is also included for an automation network.