PLC Master Clock for Mining Machine Time Synchronization
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Solution Overview
Problem
Industrial and mining machines face issues with maintaining accurate time synchronization across subsystems due to difficulties in managing time zone and Daylight Saving Time (DST) parameters, leading to data loss and inaccuracy, particularly when relying on Simple Network Time Protocol (SNTP) servers that are unstable and hard to configure.
Innovation Solution
Implementing a programmable logic controller (PLC) as a master clock that synchronizes all subsystems, allowing time zone and DST parameters to be updated only on the PLC, and using a rechargeable battery pack to maintain clock accuracy, eliminating the need for remote server synchronization and reducing DST-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each subsystem maintains its own time zone and DST parameters, then each subsystem can independently track local time, but time synchronization across subsystems becomes complex and error-prone
Solution Approach 1:
The patent consolidates time zone and DST parameter management into a single centralized location (the PLC or master subsystem) rather than maintaining separate parameters in each subsystem. This merging approach eliminates the complexity of managing multiple sets of parameters across different subsystems while ensuring consistent time synchronization throughout the industrial machine.
Solution Approach 2:
The PLC acts as an intermediary between the external time source and the various subsystems. It receives time information, processes it with the centralized time zone and DST parameters, and distributes the corrected time data to all subsystems. This intermediary role simplifies the overall system architecture by creating a single point of control for time synchronization.
2Measurement precision
If time parameters are updated on every subsystem, then each subsystem has accurate local time, but the process is time-consuming and prone to human error
Solution Approach 1:
Time zone and DST parameters are merged into a single centralized location (the PLC) rather than being maintained separately in each subsystem. When time parameters need to be updated, the change is made once at the PLC level and automatically distributed to all subsystems, reducing the update process from multiple individual operations to a single action.
Solution Approach 2:
The PLC pre-calculates and prepares the correct time data including time zone offsets and DST adjustments before distributing it to subsystems. This preliminary processing ensures that subsystems receive ready-to-use accurate time information without requiring individual parameter configuration, significantly reducing the time and effort needed for updates.
Data Source
AI summary
Systems and methods for synchronizing time between multiple systems on a mining machine. The system includes a programmable logic controller (PLC) for controlling the mining machine and for transmitting a time to synchronize computer subsystems on the machine. The PLC includes a system clock that is programmed to operate on local time. A battery pack is connected to the PLC to allow the system clock to function continuously, even when the machine is turned off. Computer subsystems request and receive time updates from the PLC. A local time on each computer subsystem is determined based on the time update received from the PLC. Each computer subsystem includes a time zone parameter set to Coordinated Universal Time (UTC) and a Daylight Saving Time (DST) parameter that is disabled. Accordingly, the local time on each computer subsystem is set to the time update value received from the PLC.