Machine Control Unit Hierarchy for Modular Motion Programming
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Solution Overview
Problem
The increasing complexity of production machine control software due to automation and the need for efficient operation, maintenance, and integration of new technologies while minimizing software effort and hardware dependencies.
Innovation Solution
A control device with multiple system modules and defined control unit levels, where basic individual control units interface directly with sensors and actuators, and higher-level units combine these to execute complex motion sequences through encapsulated services, allowing technology-neutral programming and flexible network architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the degree of automation of production machines is increased and more automation components are networked, then the functionality and productivity of the machine are improved, but the complexity of the control software increases
Solution Approach 1:
The control software is segmented into multiple control unit levels (first control unit level with basic individual control units, second control unit level with combinations of basic units, third control unit level with process coordination). This hierarchical segmentation allows complex automation tasks to be divided into manageable modules at different levels, reducing the perceived complexity while maintaining high automation functionality.
Solution Approach 2:
Service-oriented interfaces act as intermediaries between different control unit levels. The service manager and service structure provide a standardized interface layer that mediates communication between basic control units and higher-level process coordination, simplifying the integration of multiple automation components without proportionally increasing control software complexity.
2Ease of operation
If service-oriented programming methods are used to access existing libraries with base objects, then the ease of operation and programming efficiency are improved, but the adaptability to different machine technologies may be limited
Solution Approach 1:
The control device is designed with universal control unit levels and services that can handle different machine technologies (electric drives, pneumatic drives, hydraulic drives) through a common interface. The basic individual control units and service structure provide technology-neutral control, allowing the same programming approach to be applied across different machine variants and technologies.
Solution Approach 2:
The control structure allows for dynamic configuration and combination of basic individual control units at the second control unit level, enabling adaptation to different machine technologies and requirements. The service-oriented architecture permits flexible assembly of control functions to match specific machine configurations while maintaining a consistent programming paradigm.
3Manufacturing precision
If control programming is done in a technology-specific manner with direct reference to hardware, then the manufacturing precision and reliability are improved, but the ease of maintenance and renewal of machine parts deteriorates
Solution Approach 1:
The hardware-specific control logic is extracted and encapsulated within basic individual control units at the first control unit level. This extraction allows the hardware interface layer to be separated from the higher-level control logic, so that when machine parts are renewed or technologies changed, only the basic control units need to be updated while preserving the rest of the control software.
Solution Approach 2:
The service-oriented interface creates a virtual copy or abstraction layer between the physical hardware and the control logic. This allows the control software to operate on standardized service interfaces rather than direct hardware references, making maintenance and part renewal easier while preserving control precision through the service manager's coordinated control.
Data Source
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AI summary
Method for programming control devices of machines, comprising: - dividing the machines into individual control units, each comprising sensors, actuators and, if necessary, further individual control units; - dividing the motion sequences executable by an individual control unit into services, wherein commands for controlling the actuators of the basic individual control units for the execution of the respective motion sequence are encapsulated within the services.