Edge Module Timing Control for Fixed-Cycle Cloud Controllers

Solution Overview

Problem

Migrating controllers to the cloud in industrial control systems introduces network latency, leading to variable processing times and the inability to ensure fixed-cycle processing due to high network latency and reduced computational resources.

Innovation Solution

Implementing an edge module with a data generator, transmitter, receiver, and abnormality detector to manage communication with a cloud-based controller, using timestamps and serial numbers to ensure fixed-cycle processing by detecting and responding to communication anomalies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the controller is deployed in the cloud, then initial installation and update costs are reduced and flexibility is improved, but network latency increases and fixed-cycle processing cannot be ensured

Engineering Contradiction:

Improveinitial installation and update costsVSAvoidnetwork latency

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The edge module performs preliminary actions by generating control data locally and transmitting it to the cloud controller in advance. The cloud controller processes this data and returns control commands, which the edge module then executes. This preliminary action mechanism allows the system to maintain fixed-cycle processing despite cloud deployment latency, as the edge module proactively manages the control loop timing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The edge module acts as an intermediary between the cloud controller and the controlled device. It receives control commands from the cloud, processes them locally, and executes them without waiting for cloud responses. This intermediary role allows the system to benefit from cloud deployment cost savings while maintaining deterministic processing cycles through local execution autonomy.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the controller is deployed in the cloud, then flexibility and operability are improved, but simultaneity cannot be guaranteed due to Internet communication

Engineering Contradiction:

Improveflexibility and operabilityVSAvoidsimultaneity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The edge module performs preliminary actions by generating control data locally and transmitting it to the cloud controller in advance. The cloud controller processes this data and returns control commands, which the edge module then executes. This preliminary action mechanism allows the system to maintain fixed-cycle processing despite cloud deployment latency, as the edge module proactively manages the control loop timing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback mechanisms where the edge module monitors communication status and control data transmission. When communication anomalies are detected (such as missing control data or excessive latency), the edge module can switch to autonomous operation using locally generated control data, ensuring continuous and simultaneous control operations despite cloud communication variability.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If the controller is deployed in the cloud, then operational flexibility is improved, but processing speed decreases due to reduced computational resources

Engineering Contradiction:

Improveoperational flexibilityVSAvoidprocessing speed

Core Design Contradiction:

Adaptability or versatilityVSSpeed

Solution Approach 1:

The control system is segmented into two parts: cloud-based control data generation (handled by the cloud controller with its flexible computational resources) and time-critical control command execution (handled by the edge module with its local processing capabilities). This segmentation allows the cloud to provide flexibility while the edge ensures fast execution, resolving the speed-flexibility tradeoff.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The edge module acts as an intermediary between the cloud controller and the controlled device. It receives control commands from the cloud, processes them locally, and executes them without waiting for cloud responses. This intermediary role allows the system to benefit from cloud deployment cost savings while maintaining deterministic processing cycles through local execution autonomy.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20260017082A1Edge module, control system, remote control system, controller and communication method

Publication Date: 2026.01.15 KK TOSHIBA

AI summary

Provided is an edge module, a control system, a remote control system, a controller, and a communication method that enable fixed-cycle processing. An edge module includes: a data generator configured to generate first data including a serial number; a transmitter configured to assign a first timestamp to the first data and transmit the first data to a controller; a receiver configured to receive second data generated by the controller based on the first data, the second data including the serial number and the first timestamp, and to obtain a second timestamp corresponding to a reception time of the second data; and an abnormality detector configured to determine whether communication with the controller was successfully performed based on at least one of: (i) the serial number included in the second data, and (ii) a difference between the first timestamp included in the second data and the second timestamp.