Mixed-Frame Rate Logic for Industrial Control Data Sharing
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Solution Overview
Problem
Industrial control systems face challenges in sharing data between controllers with different frame rates/periods, leading to mismatched data transmission and reception times, which can cause hardware overload or erroneous timeout indications.
Innovation Solution
The implementation of mixed-frame rate logic within the industrial control system, which adjusts timeout thresholds and data processing to accommodate differing frame rates, ensuring uniform timing for data sharing across controllers with varying frame periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If controllers with different frame rates share a common physical network, then data sharing capability and system versatility are improved, but timing synchronization and communication reliability deteriorate
Solution Approach 1:
The patent introduces a timing synchronization mechanism that acts as an intermediary between controllers with different frame rates. This mechanism includes a master controller that generates timing signals and slave controllers that synchronize to these signals, mediating the timing differences between controllers with varying frame rates while maintaining reliable communication across the network
Solution Approach 2:
The patent implements dynamic timing adjustment where controllers can operate at their native frame rates while adapting to the synchronized timing framework. The system dynamically adjusts timing parameters and buffer management based on individual controller frame rates, allowing each controller to maintain its optimal operating rate while achieving overall synchronization
2Productivity
If controllers operate at different frame rates, then system flexibility and processing efficiency are improved, but data transmission timing synchronization deteriorates
Solution Approach 1:
The patent implements preliminary timing alignment through a master controller that establishes a reference timing framework before data exchange occurs. Controllers pre-synchronize their timing based on master signals and prepare data buffers in advance according to predicted transmission times, eliminating timing conflicts during actual data exchange while maintaining individual processing efficiency
Solution Approach 2:
The patent uses periodic timing signals from a master controller to coordinate data exchanges between controllers with different frame rates. Each controller synchronizes its data transmission to these periodic references, creating a structured rhythm of communication that maintains timing synchronization while allowing each controller to process data at its optimal periodic rate
3Ease of operation
If traditional fixed timing protocols are used, then communication simplicity is maintained, but system adaptability to different frame rates deteriorates
Solution Approach 1:
The patent creates a universal timing synchronization framework that can accommodate controllers with different frame rates through a common protocol. The master controller generates timing signals that can be interpreted by slave controllers regardless of their native frame rates, and the protocol automatically adapts to support multiple frame rate configurations while maintaining a single unified communication interface
Data Source
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AI summary
An industrial control system (10) is provided that includes a first control set (82), having a first frame period. The first control set (82) includes at least one first input/output (I/O) pack (60A); and at least one first controller (26A). The industrial control system (10) also has a second control set (84) with a second frame period. The second control set includes at least one second input/output (I/O) pack (60B); and at least one second controller (26B). A mixed-frame rate logic device (62) is also included with the industrial control system. This device may handle sharing of input data, output data, or both provided by the first control set (82) to the second control set (84) when the first and second frame periods are different.