Distributed Production Plant Control to Prevent Network Overload
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Solution Overview
Problem
Current production plant control systems using central PLC controllers lead to complex software code and easily result in computer and network overload, especially when using inexpensive components.
Innovation Solution
A method for operating a production plant with a distributed computer structure, where each transport drive, stop gate, diverter device, and reading device is directly connected to a separate computer, allowing data exchange both locally and via a computer network, with control processes executed in parallel and communicating through messages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a central PLC controller is used to control all transport drives, stop gates, and reading devices, then the control system is simple in structure, but the software code becomes extremely complicated and the controller is overloaded
Solution Approach 1:
The patent divides the centralized control system into multiple distributed control processes running on separate computers. Each control process manages specific transport sections independently, segmenting the control functions to reduce software complexity on each controller and distribute the computational load, thereby preventing overload while maintaining manageable system structure.
2Ease of manufacture
If multiple inexpensive computers are used in a distributed structure, then cost is reduced, but the computer network becomes overloaded due to excessive data exchange
Solution Approach 1:
The patent extracts critical real-time control data exchange from the computer network by establishing direct connections between control processes and plant components. This removes the burden of frequent control signals from the network, allowing inexpensive computers to communicate essential operational data without overwhelming the network infrastructure.
Solution Approach 2:
The patent implements local control processes that operate independently with direct access to local components, reducing the need for constant network communication. Each computer manages its local control functions with minimal network interaction, optimizing network performance while enabling the use of cost-effective computing hardware.
3Device complexity
If all control processes communicate exclusively via the computer network, then system architecture is simplified, but data exchange latency and network overload occur
Solution Approach 1:
The patent introduces direct connection pathways as intermediary channels between control processes and plant components, bypassing the computer network for time-critical control signals. This dual-path architecture maintains simplified overall structure while providing low-latency direct communication for real-time control operations.
4Device complexity
If a centralized control system is used, then system structure is simple, but the system cannot flexibly respond to component failures
Solution Approach 1:
The patent segments the control system into independent control processes that can operate autonomously. When a component fails, the affected control process can be isolated or rerouted without affecting the entire system, enabling flexible response to failures while maintaining a relatively simple distributed architecture compared to reconfigurable systems.
Data Source
AI summary
The disclosure relates to a method for operating a production plant having a plurality of processing stations, wherein the workpieces to be processed can be transported to the various processing stations by means of a transport system, wherein a plurality of computers are provided which are connected for data exchange via a computer network, the production plant being controlled by means of a plurality of control processes. According to the disclosure, during the operation of the production plant an initial decision is taken automatically about which control process is executed on which computer, wherein the initial decision is then implemented automatically.