Industrial Robot Control System Dual Internal Network Segmentation
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Solution Overview
Problem
Existing industrial robot control systems are inflexible and have limited communication abilities, requiring significant hardware and complexity when adding or replacing modules, which hinders efficient operation and scalability.
Innovation Solution
A control system with a dual-part internal network for normal and time-critical communication, where the main computer module and drive units are nodes in both parts, allowing for predictable and secure data transfer, and enabling flexible module addition and removal without altering existing hardware, using a router for connection and isolation between internal and external networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single internal network is used for all communication, then the network structure is simple, but time-critical communication cannot be guaranteed due to unpredictable delays from normal communication traffic
Solution Approach 1:
The internal network is segmented into two separate parts: a first part for normal communication and a second part for time-critical communication. This segmentation allows time-critical data to be transmitted without interference from normal communication traffic, ensuring predictable transfer times while maintaining overall system functionality.
Solution Approach 2:
A router is introduced as an intermediary device to connect the first and second parts of the internal network. The router manages data flow between the two network parts, enabling communication between modules connected to different network parts while maintaining the separation that ensures time-critical communication reliability.
2Adaptability or versatility
If modules are added or replaced in the control system, then functionality is improved, but hardware complexity and wiring requirements increase significantly
Solution Approach 1:
The internal network provides a universal communication infrastructure that all modules can connect to through standardized interfaces. Whether modules are connected to the first or second part of the network, they use the same communication protocols and connection methods, enabling easy addition and replacement without requiring specialized wiring or hardware modifications.
Solution Approach 2:
The network architecture allows modules to be replicated and added without copying complex wiring configurations. Each module connects to the network through standardized interfaces, and the router automatically manages connections, eliminating the need to replicate physical wiring paths when adding new modules.
3Adaptability or versatility
If the control system is oversized from the start to accommodate future needs, then adaptability is improved, but initial cost and hardware resources are wasted
Solution Approach 1:
The control system architecture is designed to be dynamically scalable. Modules can be added to or removed from the first or second network parts as needed, allowing the system to adapt to changing requirements without requiring pre-provisioned hardware resources. The router dynamically manages network connections based on current system configuration.
Solution Approach 2:
The system allows changes in network configuration parameters, such as which modules are connected to which network part and how data flows between them. This flexibility enables the system to optimize resource usage based on current needs rather than being constrained by initial oversized provisioning.
Data Source
AI summary
A control system for controlling an industrial robot including a manipulator. The control system includes a plurality of modules adapted to handle various functions. A first of the modules is a drive module adapted to control the motors driving the movements of the manipulator. A second of the modules is a main computer module adapted to execute a program with instructions for the movements of the manipulator and to plan the movements of the manipulator based on the executed instructions. The control system is adapted to communicate with one or more external devices via an external network. The control system includes an internal network. Each of the modules is arranged as a node in the internal network and includes communication elements for communicating with the other nodes in the internal network. The internal network includes a first part adapted for normal communication and a second part adapted for time critical communication. The main computer module is arranged as a node in both the first and second parts of the internal network and the drive unit is arranged as a node in the second part of the internal network.