Parallel Control Program Generation for Multi-Actuator Machines
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Solution Overview
Problem
Automated manufacturing machines take a long time to complete operations due to wait times when one actuator takes longer than others, causing inefficiencies in the control program generation process.
Innovation Solution
A control program generation apparatus and method that utilizes an action chart with parallel processing portions to allow simultaneous execution of element actions across multiple subperiods, reducing wait times by enabling actuators with shorter action times to proceed concurrently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the control program is generated to execute element actions sequentially in the order of subperiods, then the control logic is simple and easy to generate, but the operation time from start to end becomes long due to wait times when one actuator takes longer than others
Solution Approach 1:
The patent introduces dynamic branching logic that allows the control program to adapt its execution flow based on the duration of actuator actions. When a long-duration action is detected, the program dynamically branches to allow other actuators to proceed in parallel, rather than maintaining a fixed sequential structure. This dynamic adaptation resolves the contradiction by maintaining simple generation logic while achieving reduced operation time through conditional parallel execution.
Solution Approach 2:
The patent segments the control program into multiple branches: a first branch for actuators with shorter action times and a second branch for actuators with longer action times. This segmentation allows independent execution of different actuator groups, eliminating wait times while keeping each branch's logic relatively simple. The segmentation principle directly addresses the contradiction by organizing the control flow to minimize sequential dependencies.
2Reliability
If the control program waits for the longest-duration actuator to complete before proceeding to the next subperiod, then all actuators are synchronized, but the other actuators experience long wait times reducing productivity
Solution Approach 1:
The patent employs dynamic conditional branching that determines the execution path based on the relative durations of actuator actions. Instead of forcing all actuators to wait for the longest one (synchronous approach), the program dynamically creates parallel execution paths where actuators with shorter durations can proceed independently. This dynamic approach maintains necessary synchronization points while eliminating unnecessary wait times, thus improving productivity without compromising reliability.
Solution Approach 2:
The patent identifies long-duration actuator actions in advance and prepares alternative execution paths before execution begins. By preliminarily analyzing the action durations and setting up conditional branches, the system can immediately switch to parallel execution mode when needed, rather than discovering the optimization opportunity during runtime. This preliminary preparation enables smoother transitions and maintains synchronization where necessary while improving overall efficiency.
3Speed
If multiple actuators are made to act simultaneously in the same subperiod, then the operation speed increases, but the control complexity increases due to coordination requirements
Solution Approach 1:
The patent segments the control program into distinct branches based on actuator action durations, with the first branch handling shorter-duration actuators and the second branch handling longer-duration actuators. This segmentation simplifies the control logic within each branch while enabling parallel execution between branches. The segmentation approach reduces control complexity by creating modular, independent execution paths that can run simultaneously without requiring complex inter-branch coordination.
Solution Approach 2:
The patent changes the control parameter from a single sequential subperiod timeline to multiple parallel branches with different execution timelines. By introducing a branching parameter that separates actuators based on their action duration characteristics, the system achieves faster overall execution while keeping each branch's control logic relatively simple. This parameter change transforms the control structure from a monolithic sequential program to a modular parallel structure.
Data Source
Figure 1
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Figure 3A~3B
AI summary
A control program is automatically generated to allow a shorter overall operation time of an automated manufacturing machine. An action chart includes subperiods assigned with element actions of actuators to describe the operation of the automated manufacturing machine. Program elements for the element actions are combined in an order of the subperiods to generate the control program. The action chart includes a parallel processing portion including subperiods and their parallel subperiods. Each parallel subperiod in the parallel processing portion is assigned with an element action of a predetermined selected actuator. Each subperiod in the parallel processing portion is assigned with an element action of another actuator. In the parallel processing portion, the control program is generated by combining, in an order of the parallel subperiods, the program elements for the parallel subperiods and combining, in an order of the subperiods, the program elements for the subperiods.