Motor Controller Data Synchronization via Reference Signal Timing
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Solution Overview
Problem
In industrial equipment systems, synchronizing data collection across subordinate and superordinate controllers is challenging due to the difficulty in transmitting large data capacity through synchronous communication, and asynchronous communication lacks precise timing accuracy for data analysis.
Innovation Solution
A data collection system where a superordinate controller transmits a timing reference signal to a subordinate controller via synchronous communication, allowing the subordinate controller to record data and measure the delay time before transmitting it back via asynchronous communication, enabling synchronization of data with the transmission timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If synchronous communication is used to transmit timing reference signals, then timing accuracy is improved, but data transmission capacity is limited
Solution Approach 1:
The communication process is segmented into two distinct phases: synchronous communication for transmitting timing reference signals (high precision, low data volume) and asynchronous communication for transmitting collected data (high capacity, flexible timing). This segmentation allows each communication mode to operate in its optimal performance range, resolving the contradiction between timing accuracy and data transmission capacity.
2Quantity of substance
If asynchronous communication is used to transmit data, then data transmission capacity is improved, but timing accuracy deteriorates
Solution Approach 1:
A timing reference signal acts as an intermediary that bridges synchronous and asynchronous communication modes. The subordinate controller receives this reference signal via synchronous communication (ensuring timing accuracy) and uses it to timestamp data collected during asynchronous communication. This intermediary mechanism allows high-capacity asynchronous data transmission while maintaining timing precision through the reference signal.
Solution Approach 2:
The timing reference signal is transmitted preliminarily before data collection begins. The subordinate controller records the reception timing of this reference signal and uses it as a baseline for timing all subsequent data collections. This preliminary action establishes a timing foundation that enables accurate timing throughout the asynchronous data transmission process.
3Reliability
If delay time measurement is implemented, then data synchronization is improved, but system complexity increases
Solution Approach 1:
The subordinate controller autonomously measures the delay time between receiving the timing reference signal and starting data collection, and automatically transmits this delay information back to the superordinate controller. This self-service approach eliminates the need for complex external synchronization mechanisms, as each controller independently manages its own timing calibration, thereby improving data synchronization without proportionally increasing system complexity.
Data Source
AI summary
A data collection system includes a subordinate controller configured to control an electrical device, and a superordinate controller connected to the subordinate controller via synchronous communication and asynchronous communication to control the subordinate controller. The superordinate controller includes a reference signal transmitter to transmit a timing reference signal to the subordinate controller via the synchronous communication. The subordinate controller includes data storage configured to record data relating to the electrical device; a delay time calculator to measure a delay time from a timing at which the subordinate controller receives the timing reference signal to a timing at which the data storage starts recording the data; and a data transmitter configured to transmit the data and the delay time to the superordinate controller via the asynchronous communication or the synchronous communication.