Modular Control Device Router Configuration for Industrial Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial automation systems face issues with communication interruptions and unstable configurations due to frequent, short messages, leading to system failures and costly production stoppages, especially when communication modules are added or removed during operation.
Innovation Solution
A modular control device with integrated routers connected via a backplane bus system, where router configuration units detect available router functions and priority values to automatically configure routers as superordinate or subordinate, ensuring consistent connections to both superordinate communication networks and subordinate field-level subnetworks, and maintaining stability during module changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If communication modules are added or removed during operation to improve system flexibility and adaptability, then the system can better accommodate changing requirements, but communication interruptions and configuration instability occur leading to system failures
Solution Approach 1:
The system performs preliminary configuration actions by storing configuration data in a database before module changes occur. When a communication module is added or removed, the configuration manager retrieves pre-stored configuration data to maintain consistent system operation, preventing communication interruptions and configuration instability.
Solution Approach 2:
The configuration manager acts as an intermediary between communication modules and the control system. It manages configuration data storage and retrieval, ensuring that module changes do not cause communication interruptions or configuration instability, thus maintaining system reliability during adaptability changes.
2Adaptability or versatility
If multiple routers are used to connect to different subnetworks to improve network coverage and connectivity, then the system can communicate across multiple networks, but configuration complexity increases and inconsistent configurations may occur
Solution Approach 1:
The configuration manager provides universal configuration management functionality across all routers in the system. It stores and retrieves configuration data in a standardized manner, enabling multiple routers to connect to different subnetworks while maintaining consistent configurations and reducing overall system complexity.
Solution Approach 2:
The system replaces manual configuration management with an automated configuration manager that uses a database to store and retrieve router configurations. This substitution of manual mechanical configuration with automated data management reduces configuration complexity and prevents inconsistent configurations across multiple routers.
3Manufacturing precision
If manual configuration projection is performed before module installation to ensure proper setup, then configuration accuracy is improved, but time consumption increases and prevents rapid system deployment
Solution Approach 1:
Configuration data is stored in the database in advance before modules are installed. When modules are added or removed, the configuration manager automatically retrieves the pre-stored configuration data, ensuring configuration accuracy without requiring time-consuming manual projection procedures, thus enabling rapid system deployment.
Solution Approach 2:
The configuration manager uses stored configuration data as templates or copies that can be quickly retrieved and applied when communication modules are added or removed. This copying approach maintains configuration accuracy while significantly reducing the time required compared to manual projection, enabling rapid system deployment.
Data Source
AI summary
A method in which first routers have an extended router function for a connection to a superordinate communication network, wherein second routers include a restricted router function for a connection to a subordinate field level subnetwork, where when further first routers are present, the router configuration units of the first routers each use priority values to check which first router has the highest priority value associated with it, where the first router having the highest priority value is configured as a superordinate router for a connection to a superordinate communication network so as to configure a modular control device of an industrial automation system that includes a central unit and at least one communication module that includes a respective integrated router, where router configuration units of the first routers detect available router functions and associated priority values of other routers.