Networked Control Synchronization for Coordinated Instruments
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Solution Overview
Problem
In manufacturing sites, rearranging production lines to accommodate changing production varieties or increased production requires synchronizing control devices, which currently necessitates temporarily stopping all control devices for settings, leading to a reduction in operational efficiency.
Innovation Solution
A control system where control devices are connected through a network, allowing for synchronization of instruments across different control devices without requiring all devices to be stopped, by adjusting the control period, phase, and temporal differences in synchronization timing, enabling coordinated operation of field instruments connected to different control devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all control devices are stopped for synchronization settings, then coordination between instruments is achieved, but operational rate is reduced
Solution Approach 1:
The system performs synchronization settings in advance during the connection establishment phase between control devices. When a new control device joins the network, it automatically exchanges synchronization information (control periods, phase differences, temporal offsets) with existing devices and configures its timing parameters beforehand. This preliminary configuration enables coordinated instrument operation without requiring shutdown of running devices.
Solution Approach 2:
The patent introduces a network communication mechanism as an intermediary that facilitates synchronization between control devices. Through network message exchange, control devices share their timing parameters (control period, phase, temporal offset) and automatically calculate appropriate synchronization settings. This intermediary communication channel enables coordination without direct physical intervention or system shutdown.
2Adaptability or versatility
If control devices operate independently, then operational flexibility is maintained, but coordination between instruments connected to different control devices cannot be achieved
Solution Approach 1:
The synchronization parameters (control period, phase, temporal offset) are designed to be dynamic and adaptable rather than fixed. When control devices join or leave the network, the system dynamically adjusts synchronization settings through automatic parameter exchange and calculation. This dynamic approach maintains independent operation flexibility while enabling coordination when needed through network-based parameter sharing.
Solution Approach 2:
The system changes timing parameters (control period, phase, temporal offset) based on network conditions and device configurations. Each control device can operate with its own parameter settings independently, but when coordination is required, parameters are automatically adjusted through network communication to achieve synchronization without compromising operational flexibility.
Data Source
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AI summary
A first instrument connected to a first control device and a second instrument connected to a second control device initiate processes on a control subject in synchronization with first and second synchronization timings, respectively. When the first control device is connected to the second control device via a network, at least one of a length of a first control period, a phase difference of the first control period with respect to a second control period, and a temporal difference between a reference timing and the first synchronization timing of the first control period is adjusted in order that the first synchronization timing and the second synchronization timing coincide with each other. This makes it possible to cause a plurality of instruments connected to mutually different control devices to operate in coordination with each other while suppressing a reduction in operation rate.