Manufacturing Control Flow Reconfiguration for Device Failure Recovery
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Solution Overview
Problem
Conventional control systems struggle to easily change the linkage of multiple devices due to fixed one-to-one correspondence between functions and devices, making it difficult to adapt to device failures or changes in the manufacturing process.
Innovation Solution
A control system that manages function flow information and link information via a network, allowing for dynamic reconfiguration of device assignments and control program installation/uninstallation to facilitate seamless changes in device linkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed one-to-one correspondence between functions and devices is used, then device assignment is simple and clear, but linkage cannot be easily changed when device failure occurs
Solution Approach 1:
The patent segments the control system into three distinct components: function flow information (defining the sequence of operations), link information (defining device assignments), and control programs. This segmentation allows the link information to be independently modified without affecting the function flow, enabling flexible reassignment of devices to functions when failures occur while maintaining system simplicity.
Solution Approach 2:
The patent introduces dynamic reconfigurability by allowing the link information to be changed at runtime. The control system can dynamically update which device performs which function based on current system status, transforming a static one-to-one correspondence into a flexible many-to-many relationship that adapts to device failures and maintenance needs.
2Adaptability or versatility
If dynamic reconfiguration of device assignments is enabled, then adaptability to device failures improves, but control system complexity increases
Solution Approach 1:
The patent introduces an intermediary information structure consisting of function flow information and link information that mediates between devices and control programs. This intermediary layer manages the complexity of dynamic reconfiguration by providing a structured way to define and update device assignments without directly modifying the control logic, thus enabling flexibility while containing system complexity.
Solution Approach 2:
The patent performs preliminary actions by pre-defining function flow information and link information before actual control operations begin. This preparation phase establishes the framework for dynamic reconfiguration, allowing the system to quickly adapt to device failures by updating pre-established link information rather than creating control logic from scratch during emergencies.
3Reliability
If multiple devices can perform multiple functions, then adaptability to failures improves, but device-function mapping becomes more complex
Solution Approach 1:
The patent implements feedback mechanisms where the control system continuously monitors device status and can detect when a device fails. Based on this feedback, the system automatically or semi-automatically updates the link information to reassign functions from failed devices to alternative devices, maintaining reliable operation while managing the complexity of multiple device-function mappings through systematic monitoring and response.
Data Source
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AI summary
A control system according to an embodiment, comprises a plurality of devices and a controller. The controller stores first information representing a linkage of a plurality of functions that realize a single process and second information representing a correspondence between the devices and the functions, and controls the devices based on the first information and the second information to realize the single process.