Control Node for Flexible Industrial Automation Networks
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Solution Overview
Problem
Industrial automation systems face challenges in flexibility and adaptability due to the need for significant efforts in reconfiguring automation systems for product and process changes, despite advancements in decentralized control and Ethernet-based communication, which are not optimized for real-time applications.
Innovation Solution
A control node system with a transmission module for converting output process images into data packets and sending them at specified times, along with a receiving module for logging and converting data packets into input process images, enabling flexible communication relationships and adaptive data transmission for real-time and non-real-time data, and a network configurator for defining communication relationships dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If decentralized control with Ethernet-based communication is used, then cost advantages and ease of manufacture are improved, but real-time capability and response time are insufficient
Solution Approach 1:
The system dynamically adapts communication behavior by detecting whether a control node is a partner node (requiring real-time response) or a non-partner node (allowing store-and-forward). This dynamic adjustment of communication mode enables the system to achieve real-time capability when needed while maintaining the cost advantages of standard Ethernet infrastructure.
Solution Approach 2:
The patent changes the timing parameter of data transmission based on the partner node status. For partner nodes, data is transmitted immediately in the current control cycle; for non-partner nodes, data is stored and transmitted in the next control cycle. This parameter change optimizes both real-time performance and system cost.
2Manufacturing precision
If automation systems are designed specifically for a product, then manufacturing precision is improved, but adaptability to product and process changes deteriorates
Solution Approach 1:
The control system is segmented into independent control nodes that can be individually configured. Each control node operates autonomously with its own control cycle, allowing the system to be reconfigured for different products by changing individual node configurations rather than redesigning the entire automation system.
Solution Approach 2:
The control node is designed with universal functionality to handle both real-time partner node communications and store-and-forward non-partner node communications. This multi-functionality allows the same hardware platform to serve different manufacturing needs, improving adaptability while maintaining precision through proper communication timing.
3Loss of information
If data is transmitted to all control nodes in the network, then information completeness is improved, but communication effort and device complexity increase
Solution Approach 1:
The system applies different communication quality levels to different control nodes based on their partner status. Partner nodes receive immediate data transmission with high priority, while non-partner nodes receive data in the next control cycle. This local differentiation optimizes communication effort by avoiding unnecessary immediate transmissions to nodes that do not require real-time data.
Solution Approach 2:
Instead of transmitting data to all nodes immediately (excessive action), the system transmits data selectively based on partner status (partial action). This reduces communication effort while ensuring that all nodes eventually receive the necessary information, just at different times based on their requirements.
Data Source
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AI summary
A control node (1) for a network (3) of control nodes comprises a transmitter module (12), designed to manage data for sending in an output process layout, to convert the output process layout to a data packet and to release the data packet to the network at a given time. The control node (1) further comprise a receiver module (13), designed to log in for the data packets from one or transmitter modules of further control nodes and to convert a received data packet into an input process layout.