Networked Industrial Controller Mode Switching via Magic Packets
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Solution Overview
Problem
Current methods for changing the operating mode of networked industrial robot controllers, such as shutting down and restarting, often lead to premature wear of energy storage devices and can be time-consuming and inflexible, especially when multiple robots need to be managed simultaneously.
Innovation Solution
A method using data packets, specifically 'magic packets,' is employed over a network, like Ethernet, to switch robot controllers between operating modes, including an energy-saving mode where only essential components remain powered, allowing for controlled shutdown and restart without complete disconnection from the external power supply, thereby reducing energy consumption and extending the life of energy storage devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the main switch is operated to completely disconnect the system from external power supply, then the system is shut down, but the energy storage device is strained and its lifespan is shortened
Solution Approach 1:
The system performs preliminary actions by saving current data to a freeze file before complete disconnection, and pre-charges the energy storage device during partial operation modes, so that when the main switch is operated, the energy storage device is not suddenly strained
Solution Approach 2:
The patent introduces different operating modes (first, second, third modes) where different components are disconnected from power supply. In the second operating mode, only non-essential components are disconnected while essential components remain powered, allowing the energy storage device to be gradually charged without full system operation
2Reliability
If the main switch is operated to completely disconnect the system from external power supply, then the system is shut down, but the shutdown and data saving process is time-consuming
Solution Approach 1:
The system performs preliminary data saving to freeze files during normal operation and in partial shutdown modes, so that when complete disconnection occurs, the shutdown process is already partially complete, reducing the time needed for full system restart
Solution Approach 2:
The patent implements dynamic operating modes that allow flexible transitions between different shutdown levels. The controller can operate in partial shutdown modes where only non-essential components are powered down, enabling faster recovery while maintaining essential functions
3Loss of energy
If the controller is disconnected from external power supply, then energy consumption is reduced, but a complete system restart is required which is time-consuming
Solution Approach 1:
The patent segments the system shutdown into multiple levels: first operating mode (partial disconnect), second operating mode (more extensive disconnect), and third operating mode (complete disconnect). This segmentation allows the system to achieve energy reduction without always requiring complete disconnection, thus avoiding full system restarts
Solution Approach 2:
The system saves data to freeze files in advance during normal operation and partial shutdown modes, so that when power is restored, the system can quickly resume operation using saved data rather than performing a complete restart
4Reliability
If a damaged or insufficiently charged energy storage device is used, then the controlled shutdown and data saving are impaired, but the system needs to be shut down
Solution Approach 1:
The patent introduces a second operating mode where only non-essential components are disconnected from power supply while essential components remain powered. This allows the system to achieve energy reduction without relying on the energy storage device, thus avoiding the problems of damaged or insufficiently charged energy storage
Solution Approach 2:
The system pre-charges the energy storage device during partial operation modes and performs preliminary data saving, so that when complete shutdown is necessary, the energy storage device is already in a sufficient state to handle the shutdown process reliably
Data Source
Figure 1~2
AI summary
The method involves sending a data packet by a network of a networked industrial controller. The data packet is received through a receiving unit of an industrial controller. The operating mode of the industrial controller is changed from one operating mode to another operating mode on the basis of the received data packet. The data packet is addressed to the industrial controller. Groups of components of the industrial controller are supplied with energy. The groups are different in the two operating modes. Independent claims are included for the following: (1) a computer program for executing the method for changing the operating mode of an industrial controller; and (2) a computer program product with a program code.