Industrial Controller Asynchronous Data Transfer Without Polling
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Solution Overview
Problem
The existing production systems face increased processing loads during data collection due to the need for regular polling between external devices and industrial machines, leading to inefficiencies in data transmission and processing.
Innovation Solution
A production system is designed to reduce processing loads by writing collection target data into an asynchronous area instead of a synchronous area, eliminating the requirement for polling and utilizing an asynchronous area divided into channels for efficient data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polling is performed between external device and industrial machine for data collection, then data can be transmitted, but processing load increases
Solution Approach 1:
The patent applies preliminary action by having the controller proactively push data to the external device when data becomes available in the asynchronous area, rather than waiting for the external device to poll. The controller monitors the asynchronous area and automatically transmits data when write operations complete, eliminating the need for continuous polling and reducing processing load on both devices.
2Reliability
If synchronous area is used for data storage, then data can be accessed regularly, but processing load increases due to polling requirement
Solution Approach 1:
The patent segments the storage area into two distinct parts: a synchronous area for data that requires regular polling and time-synchronization, and an asynchronous area for data that can be transmitted immediately when available. This segmentation allows the system to handle different data types with appropriate access methods, reducing the overall processing load by eliminating polling for asynchronous data while maintaining reliability for synchronous data.
3Loss of information
If polling is performed for data collection, then data can be collected, but time is wasted due to regular monitoring requirements
Solution Approach 1:
The patent implements self-service by enabling the controller to automatically manage data transmission without requiring external polling. The controller monitors the asynchronous area, detects when data is written, and autonomously transmits the data to the external device. This self-service mechanism ensures complete data collection while eliminating wasted polling time, as the system only acts when necessary.
4Reliability
If synchronous area is used for data storage, then data can be stored, but storage efficiency decreases due to synchronization requirements
Solution Approach 1:
The patent segments the storage area into synchronous and asynchronous areas, improving storage efficiency by allowing the asynchronous area to be used for data that does not require synchronization. This segmentation enables the system to store more data overall while maintaining reliability for data that truly needs synchronous access, as the asynchronous area can be freely written to without synchronization overhead.
Data Source
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AI summary
Provided is a production system (1) including: an industrial controller (20) configured to control an industrial machine (30). The industrial controller (20) includes an acquisition module (204) configured to acquire data relating to an operation of at least one of the industrial controller (20) or the industrial machine (30). The industrial controller (20) includes: a synchronous area regularly subjected to synchronization; an asynchronous area different from the synchronous area; a writing module (205) configured to write the data into the asynchronous area; and a data transmission module (213) configured to transmit the data written in the asynchronous area to an external device (10).