Predictive Field Device Control for Networked Motion Synchronization

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Solution Overview

Problem

Existing control systems face challenges in synchronizing master-slave operations across different devices, such as rotational shafts and robots, due to communication cycle delays, requiring manual user corrections.

Innovation Solution

A control device that utilizes an estimator to calculate the position of a field device in a subsequent cycle and a processor to determine command values for coordinated operation, allowing periodic communication and synchronization between field devices through a network, using EtherCAT standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If periodic communication is used to control multiple field devices through a network, then device integration and communication efficiency are improved, but communication delays cause desynchronization between master and slave operations

Engineering Contradiction:

Improvecommunication efficiencyVSAvoidsynchronization accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The estimator calculates the position of the first field device in the second cycle (future cycle) based on its position in the first cycle. This preliminary calculation of future position allows the system to compensate for communication delays by using predicted rather than current position data, enabling the slave device to operate in coordination despite the time lag in command transmission and reception

Inventive Principle:

Principle #10Preliminary action

2Reliability

If manual correction methods are used to adjust master-slave operation delays, then synchronization can be achieved, but system complexity and operational burden increase

Engineering Contradiction:

Improvesynchronization accuracyVSAvoidoperational burden

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The estimator automatically calculates the position of the first field device in the second cycle based on its position in the first cycle and the program requirements. This self-service mechanism eliminates the need for manual delay correction by users, as the system autonomously computes the necessary position compensation and generates appropriate command values for coordinated slave device operation

Inventive Principle:

Principle #25Self-service

3Ease of operation

If position-based command values are transmitted to slave devices, then operational coordination is achieved, but communication cycle delays cause timing mismatches

Engineering Contradiction:

Improvecoordination controlVSAvoidcommunication delay

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12111629B2Control device

Publication Date: 2024.10.08 OMRON CORP

AI summary

To cause multiple field devices to operate together in coordination in accordance with a predetermined program through a network allowing periodic communication, a control device includes an estimator that calculates, based on a position of a first field device in a first cycle, a position of the first field device operable in accordance with a first program in a second cycle following the first cycle, and a processor that determines, based on the first program, a first command value to cause the first field device to operate, transmits the first command value to the first field device through an interface allowing communication with the field devices, determines, based on the estimated position and a second program, a second command value to cause a second field device to operate in coordination with the first field device, and transmits the second command value to the second field device through the interface.