Dual-System Robot Controller Architecture for Computing Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing industrial robot controllers face complexity in structure, difficulty in programming, weak computing power, and challenges in coordinating control of multiple axes, leading to unreliable systems and increased costs with limited flexibility for adding new functions.
Innovation Solution
A dual system component-based industrial robot controller employing a router manager, soft bus, and modular architecture with separate standard and real-time operating systems, enabling open architecture and user-developed function modules, and allowing for flexible hardware connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single CPU structure or centralized control architecture is used, then the structure is simple, but the computing power is weak and cannot handle complicated calculations like dynamic control
Solution Approach 1:
The controller is divided into multiple independent CPU modules (motion control CPU, PLC CPU, IO CPU, etc.), each responsible for specific functions. This segmentation allows each module to be optimized for its specific task while collectively providing high computing power for complex calculations.
Solution Approach 2:
The patent transitions from a single-dimensional centralized control to a multi-dimensional distributed control architecture. By adding spatial distribution of multiple CPUs across different functional modules, the system achieves both structural modularity and enhanced computing power simultaneously.
2Power
If PC plus DSP-based motion control card structure is used, then computing power is improved, but the structure becomes complicated and programming becomes difficult
Solution Approach 1:
The patent implements a universal control architecture where multiple CPU modules follow the same standardized interface and communication protocols. This universality allows the system to maintain high computing power while reducing structural complexity, as each module can be independently developed and integrated using the same framework.
Solution Approach 2:
The controller adopts a dynamic modular architecture where functional modules can be dynamically configured, added, or removed. This flexibility allows the system to adapt to different application requirements without requiring complex reconfiguration, simplifying both structure and programming.
3Adaptability or versatility
If more axes coordination control is required, then the control capability is improved, but the wiring becomes complex and debugging and maintenance become difficult
Solution Approach 1:
The patent replaces physical wiring connections with digital communication networks. The IO modules and field devices communicate through standardized digital interfaces and protocol stacks, eliminating complex physical wiring while maintaining enhanced control capability for multiple axes coordination.
Solution Approach 2:
The protocol stack module acts as an intermediary layer between different CPU modules and field devices. It standardizes communication protocols and data formats, allowing multiple axes to be coordinated without increasing wiring complexity, as all communications are managed through this intermediary software layer.
4Ease of operation
If open architecture with real-time system on PC is used, then programming flexibility is improved, but the system reliability decreases and adding new functions requires architecture modification
Solution Approach 1:
The patent separates the real-time control functions into dedicated real-time CPU modules independent of the PC-based operating system. This segmentation ensures that real-time reliability is maintained through specialized hardware while programming flexibility is provided through standardized interfaces, allowing new functions to be added without modifying the core real-time architecture.
Data Source
AI summary
A dual system component-based industrial robot controller having a standard operating system, a real-time operating system, a route management module, a soft bus, a driver management module, a motion control module, a PLC module, an IO module, a teach pendent interface module and a protocol stack module. The controller employs a component-based structure and the components are operated respectively under a non real-time standard operating system and a real-time operating system, and supports distributed processing. The communications and function calls among the components are carried out by the route management module and the soft bus. The components in communication are managed through the route management module. The driver management module provides communications among other modules with a consistent interface which accords to the DS402 standard, and a servo driver that accords to this interface standard can be readily integrated into the controller. A user can develop function module components and add the same to the system, and the open-type interface of the controller enables the controller to connect hardware without limitations.