Dual-Network EtherCAT Control Switching for Fault Tolerance
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Solution Overview
Problem
Existing ring-type EtherCAT networks face challenges in maintaining communication when faults occur at multiple locations or in the control apparatus, leading to communication disruptions.
Innovation Solution
A communication system with active and standby control apparatuses connected through dual networks, allowing the main control apparatus to switch control data transmission between them when faults are detected, ensuring continued communication and fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single active control apparatus is used, then device complexity is reduced, but fault tolerance is insufficient when the active control apparatus fails
Solution Approach 1:
A standby control apparatus is prepared in advance with the capability to take over control functions. The standby apparatus maintains readiness by receiving control data and being able to switch to active control mode, ensuring fault tolerance without requiring complex real-time reconfiguration.
Solution Approach 2:
The standby control apparatus serves as a functional copy of the active control apparatus, maintaining the same control capabilities and data processing functions. This copying approach provides fault tolerance while keeping the system configuration relatively simple.
2Reliability
If dual networks with active and standby control apparatuses are implemented, then fault tolerance is improved, but device complexity increases
Solution Approach 1:
The first and second networks are merged at the controlled device level, where each controlled device has both a first interface connected to the first network and a second interface connected to the second network. This merging allows the system to maintain communication through either network, providing fault tolerance while sharing common controlled devices between both networks.
3Reliability
If the main control apparatus switches to standby control apparatus upon fault detection, then communication continuity is improved, but response time for fault detection and switching is extended
Solution Approach 1:
The main control apparatus monitors the operation of the active control apparatus and the status of control data transmission through feedback mechanisms. When communication failures or faults are detected via feedback from the networks or controlled devices, the system can trigger a switch to the standby control apparatus, balancing detection time with communication continuity.
Data Source
AI summary
A communication system includes a plurality of controlled devices each including communication IFs compliant with EtherCAT standards; network connected to communication IF of each of controlled devices, network connected to communication IF of each of controlled devices; control apparatus capable of sending out first control data for controlling controlled devices to network; control apparatus capable of sending out second control data for controlling controlled devices to network; and main control apparatus that performs first control that causes control apparatus to send out the first control data. Main control apparatus further performs second control that causes control apparatus to send out the second control data when the sent first control data fails to reach at least one of controlled devices.