Master Signal Synchronization for Multi-Vendor Automation Control
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Solution Overview
Problem
Modern manufacturing and automation systems face complexity in integrating products from different manufacturers due to varying communication protocols and latency issues, making it difficult to coordinate activities between hardware from different vendors, especially in real-time scenarios.
Innovation Solution
A method and system for managing automation systems by determining a master signal and communication protocol, incorporating lag time and compensation profiles based on communication protocol characteristics and data characteristics, and using compensation algorithms to synchronize synchronous elements, ensuring efficient operation across different vendors' equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different communication protocols are used by automation systems from different manufacturers, then hardware interchangeability is limited and vendor lock-in occurs, but protocol conversion using industrial computers increases system complexity and introduces latency
Solution Approach 1:
The patent implements a universal master signal architecture where all synchronous elements regardless of manufacturer communicate through a standardized master signal interface. This eliminates the need for protocol conversion by making the master signal interface multi-functional and compatible with different vendors' equipment, thereby improving hardware interchangeability without increasing complexity
Solution Approach 2:
The master signal acts as an intermediary that mediates communication between automation elements from different manufacturers. Instead of converting between different protocols, the system introduces a universal master signal that all elements synchronize to, simplifying the integration process and eliminating vendor lock-in while maintaining low latency
2Adaptability or versatility
If protocol conversion is implemented using industrial computers, then communication between different manufacturers' equipment is enabled, but real-time communication performance deteriorates due to latency
Solution Approach 1:
The patent extracts the protocol conversion function from heavy industrial computers and implements it directly in the automation elements themselves through the master signal synchronization mechanism. This eliminates the intermediate conversion step that caused latency, enabling real-time communication while maintaining multi-vendor compatibility
Solution Approach 2:
The system replaces the mechanical approach of protocol conversion through industrial computers with a signal-based synchronization approach using master signals. This substitution eliminates the processing delays inherent in software-based protocol conversion and achieves real-time communication performance
3Reliability
If synchronization coordination is implemented among hardware from different manufacturers, then system integration is achieved, but complexity increases due to protocol differences and latency
Solution Approach 1:
The patent changes the synchronization parameter from protocol-based communication to time-based master signal synchronization. All automation elements synchronize to the same master signal timeline, which simplifies coordination regardless of manufacturer differences. This parameter change reduces integration complexity while maintaining reliable synchronization
Data Source
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AI summary
A method for managing an automation system involving a plurality of synchronous elements, the method including: designating a master signal for controlling the plurality of synchronous elements; determining a communication protocol for communicating the master signal to the plurality of synchronous elements; determining a compensation profile for each of the plurality of synchronous elements based on the communication protocol and characteristics of each of the plurality of synchronous elements; and utilizing the compensation profile in the control of the automation system. A system for managing an automation system involving at least two synchronous elements, the system including: a first controller for controlling a first synchronous element; a second controller for controlling at least a second synchronous element; a configuration module for configuring at least the second synchronous element; a memory storing instructions that, when executed by the second controller, cause the second controller to perform the method above.