Dual-OS Motion Control for Multi-Protocol Device Synchronization
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Solution Overview
Problem
Current motion control systems lack the ability to seamlessly integrate and control multiple control target devices with different communication protocols on a single computer running both non-real-time and real-time operating systems, limiting versatility and increasing costs.
Innovation Solution
A motion control program that operates on a computer with both non-real-time and real-time OS, utilizing a reception unit for user commands, a control unit for interpolation command generation, and communication modules for protocol conversion, enabling synchronization and control of devices with diverse communication standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated motion controller hardware is used, then real-time performance and control accuracy are improved, but device cost and configuration complexity increase
Solution Approach 1:
The motion control device is designed to support multiple communication protocols (EtherCAT, RTEX, MECHATROLINK, CANopen) and control various types of control target devices (servo motors, stepping motors) through a single unified platform. The communication module automatically detects and adapts to different protocols, eliminating the need for separate dedicated controllers for each device type and reducing overall system complexity while maintaining real-time performance.
2Adaptability or versatility
If multiple control target devices with different communication protocols are connected to one computer, then device versatility is improved, but the ability to maintain real-time control accuracy deteriorates
Solution Approach 1:
The motion control device is divided into functionally independent modules: a reception unit that operates on the non-real-time OS for user interface and program execution, and a control unit that operates on the real-time OS for precise motion control. This segmentation allows the system to maintain real-time control accuracy for multiple devices with different protocols while providing versatile user interaction capabilities through the non-real-time OS.
Solution Approach 2:
The communication module acts as an intermediary between the reception unit and control unit, and between the control device and various control target devices with different communication protocols. It translates and adapts communication signals between different protocols, enabling a single computer to control multiple devices with different protocols while maintaining real-time control accuracy through the real-time OS.
3Ease of operation
If a non-real-time OS is used for motion control, then user interface familiarity and cost are improved, but control timing precision and synchronization deteriorate
Solution Approach 1:
The system separates the user interface functions running on the non-real-time OS from the control execution functions running on the real-time OS. The reception unit on the non-real-time OS provides familiar user interface operations and program creation, while the control unit on the real-time OS ensures precise timing control and synchronization for motion control operations, thus resolving the contradiction between ease of operation and control precision.
Data Source
AI summary
A motion control program that causes a computer to function as: a reception unit on a non-real-time OS that receives a control command indicating an operation to be performed by a control target device over a plurality of motion control cycles, and stores control command information indicating a content of the received control command in a control command channel that is reserved in a shared memory referable from the non-real-time OS and a real-time OS; a storage unit that obtains the control command information from the control command channel and stores it in a FIFO queue; a command processing unit that retrieves the control command information from the FIFO queue and passes it to a fixed-cycle processing unit; the fixed-cycle processing unit transmits an interpolation command to the control target device for each motion control cycle, based on the control command information.