Smart Controller Backup for Signal Traffic Abnormalities

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing control platforms for electronic devices face challenges in maintaining uninterrupted operation during signal traffic abnormalities between outer and inner controllers, particularly due to outages or upgrades in edge platforms, which can lead to costly interruptions in applications like industrial drives and wind farms.

Innovation Solution

A control arrangement comprising an inner controller and a smart controller that provides substitute instruction signals to ensure continuous operation of electronic devices. The smart controller, equipped with a machine learning model, detects abnormalities in signal traffic and generates substitute signals to maintain the electronic device at a steady-state operating point or transition it to a safe mode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If outer controller software is upgraded or maintained, then control platform reliability is improved, but signal traffic interruption occurs causing electronic device operation to stop

Engineering Contradiction:

Improvecontrol platform reliabilityVSAvoidoperation interruption duration

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The smart controller is pre-trained with a machine learning model during normal operation to learn the outer controller's instruction signal patterns. This preliminary learning enables the smart controller to generate substitute instruction signals when the outer controller is unavailable for software upgrades or maintenance, preventing operation interruption.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The smart controller acts as an intermediary between the outer controller and the inner controller. When the outer controller is unavailable, the smart controller receives sensor signals from the inner controller and generates substitute instruction signals based on its trained machine learning model, maintaining the control signal flow during outer controller maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If control functionalities are concentrated at the edge platform, then system integration is improved, but vulnerability to signal traffic abnormalities increases

Engineering Contradiction:

Improvesystem integration capabilityVSAvoidsignal traffic reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The control system is segmented into three independent components: the outer controller for high-level control, the smart controller with machine learning model for signal substitution, and the inner controller for real-time control. This segmentation allows the smart controller to detect signal traffic abnormalities and provide substitute signals, maintaining reliability while preserving edge platform integration capabilities.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If wireless communication technology is used, then communication flexibility is improved, but network outage and interference susceptibility increases

Engineering Contradiction:

Improvecommunication flexibilityVSAvoidnetwork outage and interference

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The smart controller serves as a mediator that receives sensor signals from the inner controller and generates substitute instruction signals when wireless communication between the outer and inner controllers is interrupted or interfered with. This intermediary function maintains control continuity despite wireless communication vulnerabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If machine learning model is trained during normal operation, then substitute signal generation capability is improved, but training data availability is reduced during abnormalities

Engineering Contradiction:

Improvesubstitute signal generation capabilityVSAvoidtraining data availability

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The machine learning model is trained in advance during normal operation when abundant training data is available. The trained model is then stored in the smart controller's memory, enabling it to generate substitute instruction signals during abnormalities without requiring real-time training data, thus resolving the contradiction between training capability and data availability.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250044750A1Control arrangement, method, and computer program for controlling an electronic device, control platform comprising the control arrangement, method for training a machine learning model, and computer-readable medium

Publication Date: 2025.02.06 ABB (SCHWEIZ) AG

AI summary

A control arrangement for controlling an electronic device, is provided. The control arrangement comprises: an inner controller being coupled to the electronic device and being configured for generating at least one control signal for controlling the electronic device depending on at least one instruction signal from an outer controller; and a smart controller coupled to the inner controller and being configured for providing at least one substitute instruction signal for controlling the electronic device to the inner controller if an abnormality related to a signal traffic between the inner controller and the outer controller is detected.