PLC Dual-Processor Control for High-Frequency Data Analysis
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Solution Overview
Problem
Existing programmable logic controller systems transfer all analysis target data to an analyzer, leading to time-consuming data transfer and inability to perform short-time, high-frequency data analysis and feedback.
Innovation Solution
A programmable logic controller with a first module connected to an external device and a second module, utilizing a first processor operable by a real-time operating system for efficient data analysis and a second processor for additional computations when needed, allowing efficient data processing without extensive network transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all analysis target data is transferred from the controller to an analyzer through the network, then the analysis can be performed using a general-purpose operating system, but the data transfer time increases and high-frequency data analysis cannot be achieved
Solution Approach 1:
The patent segments the data processing function by dividing the controller into a first processor (real-time OS) and a second processor (general-purpose OS). The first processor handles data collection and preliminary processing, while the second processor performs complex analysis tasks. This segmentation allows the system to maintain real-time responsiveness while utilizing general-purpose computing capabilities for analysis.
Solution Approach 2:
The patent merges the real-time control functions and general-purpose analysis functions into a single integrated controller system. By combining both processor types within one controller, the system achieves both real-time performance and sophisticated analysis capabilities without requiring separate devices, thus eliminating network transfer delays.
2Reliability
If data is transferred through the network between modules, then communication bandwidth can be divided for control data and information data, but small volume data with additional transfer information has a larger size ratio that reduces efficiency
Solution Approach 1:
The first processor performs preliminary data processing and filtering before analysis, preparing the data in advance. This preliminary action reduces the volume of data that needs to be transferred and processed, minimizing the impact of additional transfer information on overall efficiency while ensuring control data integrity.
Solution Approach 2:
The first processor acts as an intermediary between the data collection interface and the second processor. It preprocesses data, filters out unnecessary information, and prepares optimized data packets for analysis, reducing the overhead ratio of additional transfer information while maintaining reliable communication.
Data Source
AI summary
A programmable logic controller (PLC) system includes a PLC module connectable to an external device (19) and a data collection-analysis module (13). The data collection-analysis module (13) is connected to the PLC module through signal lines (16). The data collection-analysis module (13) includes a real-time processor (21) that is operable by a real-time operating system and performs, when target data collected from the PLC module through the signal lines (16) has a size less than or equal to a size threshold, a computation on the target data to generate control data for controlling the external device (19), and a general-purpose processor (31) connected to the real-time processor (21) to perform, when the real-time processor (21) does not perform a computation on the collected target data, a computation on acquired target data to generate the control data.