Distributed Logic Control with Self-Setup for Fault-Tolerant Automation
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Solution Overview
Problem
Existing control systems relying on programmable logic controllers (PLCs) are costly, not scalable, difficult to implement, and prone to single-point failures due to their centralized control architecture.
Innovation Solution
A distributed logic control apparatus comprising enhanced intelligent devices with processors and algorithms that communicate through a data network, enabling self-setup and implicit/explicit cross-signaling for distributed control, reducing reliance on a single PLC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a programmable logic controller (PLC) is used to control all controlled elements, then control functionality is provided, but the PLC becomes costly and creates a single point of catastrophic failure
Solution Approach 1:
The control system is segmented into multiple intelligent devices, each responsible for controlling specific controlled elements. This distributes the control functionality across multiple independent units rather than relying on a single PLC, thereby eliminating the single point of failure and improving system reliability while reducing the complexity burden on any single device.
2Adaptability or versatility
If a PLC with greater processing capability is used to control more controlled elements, then control capability is improved, but the system becomes less scalable and requires replacement of existing PLC
Solution Approach 1:
The system is divided into multiple intelligent devices that can be independently added or removed from the network. Each device maintains its own processing capability for controlling assigned elements, allowing the system to scale by simply adding more devices to the data network rather than replacing a central PLC with increasingly powerful models.
Solution Approach 2:
Each intelligent device is designed with universal functionality to control various types of controlled elements through standardized data network communication. This multi-functionality allows any device to potentially control any elements, providing flexibility and adaptability while maintaining system scalability through uniform device architecture.
3Manufacturing precision
If manual programming of PLC is performed to control specific system configuration, then control precision is achieved, but implementation becomes difficult and requires reprogramming for changes
Solution Approach 1:
The intelligent devices automatically determine their own identities, addresses, and control relationships through self-identification and self-setup operations when joining the data network. This eliminates the need for manual programming of control logic for system configuration, allowing precise control to be achieved automatically while significantly easing implementation and enabling easy reconfiguration when system changes occur.
4Extent of automation
If a single PLC performs all control operations, then control functionality is centralized, but the system lacks fault tolerance and is prone to catastrophic failures
Solution Approach 1:
Control automation is segmented across multiple intelligent devices, each independently performing control operations for its assigned elements. This distribution of automated control functions ensures that a failure in one device does not propagate to the entire system, providing fault tolerance while maintaining high levels of automation through coordinated operation of all devices on the data network.
Data Source
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AI summary
A distributed logic control apparatus is usable to control a system and includes a plurality of enhanced intelligent devices and a network protocol control that are connected with a data network. The intelligent devices each have a processor apparatus and an algorithm operable thereon that enables each intelligent device to control a corresponding part of the system. Other algorithms on the intelligent devices provide an advantageous setup operation that enables the intelligent devices to cooperate with one another in a self-setup operation.