Safety Controller Synchronization for Asynchronous Multi-Axis Monitoring
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Solution Overview
Problem
Existing industrial automation systems face challenges in synchronizing detection values across multiple axes and sensors, particularly in asynchronous operations, leading to inaccuracies and safety concerns due to temporal concurrency and asynchronicity in clock cycles.
Innovation Solution
A method and safety-related control unit that synchronize detection values by adjusting individual acquisition values to a common counter increment, using a telegram filter to ensure they are aligned in time, allowing for the generation of accurate monitoring values despite asynchronous operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If asynchronous operation is used to allow independent clock cycles for each axis, then system flexibility and independence are improved, but temporal synchronization and monitoring accuracy deteriorate
Solution Approach 1:
The patent applies preliminary action by determining counter increments for each axis based on previously received telegrams and stored counter values before generating the monitoring value. This allows the system to pre-calculate the necessary adjustments to synchronize asynchronous position and speed values from multiple axes to a common time reference, ensuring temporal accuracy while maintaining asynchronous operation independence
Solution Approach 2:
The patent introduces an intermediary mechanism in the form of a telegram filter that processes telegrams from multiple axes independently. This filter determines counter increments for each axis based on its own telegram reception timing, acting as an intermediary that translates asynchronous incoming data into synchronized monitoring values without requiring the axes to share a common clock cycle
2Measurement precision
If clock synchronization is implemented across all axes, then temporal accuracy is improved, but system complexity and coordination requirements worsen
Solution Approach 1:
The patent applies segmentation by dividing the synchronization task into independent segments for each axis. Instead of implementing a centralized clock synchronization system across all axes, the telegram filter processes each axis independently, determining counter increments based on individual telegram reception times. This segmented approach maintains temporal accuracy while avoiding the complexity of coordinating multiple axes to a common clock
3Adaptability or versatility
If non-clock-synchronous cyclic calling is used for acquiring values, then system independence is improved, but reliability of synchronized monitoring values deteriorates
Solution Approach 1:
The patent implements feedback by using the actual reception timing of telegrams to adjust the counter increments for each axis. The telegram filter continuously monitors when telegrams are received and uses this feedback information to determine the appropriate counter increment that will synchronize the monitoring value to the correct time reference, ensuring reliability despite non-clock-synchronous acquisition cycles
Data Source
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AI summary
The invention relates to a method for synchronising measurement values delivered in an individual measurement phase, wherein the measurement values are processed by a safety-oriented controller in a monitoring phase in accordance with a safety function, wherein, in a current monitoring cycle of the monitoring phase, individual counter increments of the measurement values are compared with one another in comparison with a previous monitoring cycle, and a maximum counter increment is determined, wherein the measurement values that do not have the maximum counter increment are adjusted on the basis of the maximum counter increment, wherein on the basis of the adjusted measurement value(s) and the measurement value(s) associated with the maximum counter increment at least one monitoring value is established by the safety function. The invention also relates to an associated safety-oriented control unit.