I/O Module Primary Central Unit Selection via Fieldbus States
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems for detecting failures in industrial programmable logic controllers rely heavily on communication between central units, which can lead to prolonged detection times and require specific central units and software, increasing costs and complexity.
Innovation Solution
An input/output module with processing means that communicates with both central units via separate field buses, allowing for the selection of a primary central unit based on bus and unit operating states, prioritizing consistent information, and enabling fallback solutions to reduce reaction time and redundancy checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two central units are permanently in communication to ensure redundancy, then system reliability is improved, but detection time increases and specific central units with dedicated software are required
Solution Approach 1:
The patent divides the redundancy function into two independent parts: a first central unit with a first processor and a second central unit with a second processor. Each processor independently executes the same application program and communicates with input/output modules via separate field buses, eliminating the need for permanent communication between central units while maintaining reliability through independent operation.
Solution Approach 2:
The patent introduces field buses as intermediary communication channels between central units and input/output modules. Each central unit communicates independently through its own field bus, allowing parallel operation without direct communication between central units, thus reducing detection time while maintaining system reliability.
2Reliability
If two central units are permanently in communication to ensure redundancy, then system reliability is improved, but device complexity increases due to dedicated software requirements
Solution Approach 1:
The patent makes each central unit universally capable by equipping both the first and second processors with identical communication interfaces and the ability to execute the same application program. This universality allows either unit to independently control the system without requiring specialized dedicated software, reducing device complexity while maintaining reliability.
Solution Approach 2:
The patent changes the operational parameters of the central units by allowing them to operate independently with the same configuration and software. Instead of requiring one unit to be master and the other slave with dedicated communication protocols, both units operate with equal parameters, simplifying the system architecture.
3Stability of the object's composition
If information exchange between central units and input/output modules follows cycles based on central unit clock frequency, then system coordination is maintained, but detection time increases
Solution Approach 1:
The patent implements preliminary action by having each central unit independently and continuously execute the application program and monitor system state before any failure occurs. This continuous independent monitoring allows immediate detection of failures without waiting for scheduled communication cycles between central units.
Solution Approach 2:
The patent ensures continuity of useful action by having both central units continuously execute the application program and communicate with input/output modules independently through their respective field buses. This continuous independent operation maintains system coordination while enabling faster failure detection compared to periodic inter-unit communication.
Data Source
Figure 1
Figure 2
AI summary
The module (6) has communication units communicating with central units (2a, 2b) by fieldbuses (5a, 5b), respectively. A processing unit i.e. microprocessor, establishes selection of a primary central unit from the central units by taking into account a functioning state of each fieldbus, a functioning state of each central unit and consultation of information provided by the central units. The processing unit controls outputs of the module according to information received from the primary central unit. An independent claim is also included for a modular programmable industrial automaton comprising a sensor and/or an actuator.