Synchronized Control Command Timing for Linked Factory Automation
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Solution Overview
Problem
Existing factory automation control systems require multiple dedicated devices for synchronous processing, leading to redundancy and an inability to realize all types of programs, such as ladder, CNC, and robot programs, with a single control device.
Innovation Solution
A control system configuration that adjusts the output timing of control commands based on synchronized timers between control devices, allowing for accurate timing adjustment and cooperative operation between control applications, enabling linkage with CNC machine tools or robots even in combined control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated control devices are used for synchronous processing, then processing capability and reliability are improved, but device complexity and redundancy increase
Solution Approach 1:
The patent combines multiple control functions (PLC, CNC, robot control) into a single integrated control device. The control device includes a main body with a processor that can execute different types of control programs and coordinate multiple control objects simultaneously, eliminating the need for separate dedicated control devices while maintaining synchronous processing capability
Solution Approach 2:
The control device is designed with multi-functionality to perform various control tasks including sequence control, motion control, and robot control through a single device. The processor can adaptively execute different control algorithms and communicate with diverse control objects, making one device replace multiple specialized devices
2Device complexity
If a single control device is used to consolidate multiple functions, then device complexity is reduced, but the ability to execute all types of programs (ladder, CNC, robot) simultaneously is limited
Solution Approach 1:
The control device incorporates a universal processor capable of executing multiple programming languages and control algorithms (ladder logic, G-code, robot control programs). The device can dynamically switch between different control modes and simultaneously manage diverse control objects with different program types
Solution Approach 2:
The control device employs dynamic task scheduling and priority management mechanisms. The processor can dynamically allocate resources, adjust execution priorities of different control tasks, and adaptively manage multiple programs based on real-time system demands, ensuring all program types can be executed effectively
3Productivity
If control commands are output without timing adjustment, then processing speed is improved, but timing accuracy and cooperative operation between control applications deteriorate
Solution Approach 1:
The control device incorporates timing feedback mechanisms where the processor monitors the actual output timing of control commands and compares it with the scheduled timing. Based on this feedback, the system dynamically adjusts future command output timing to maintain synchronization accuracy across different control applications
Solution Approach 2:
The control device performs preliminary timing calculation and command buffering before actual command output. The processor pre-calculates the optimal output timing for control commands based on scheduled operation times, and buffers commands to ensure they are output at the precise moment required for synchronous operation
Data Source
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AI summary
A configuration of control device capable of linking control applications even in a control system that combines a control device with another control device is provided. A first control device includes: a first program execution part outputting a first control command at every first cycle; a parsing part parsing at least a part of a first application program at every second cycle to sequentially generate an internal command; a command calculation part outputting a second control command at every first cycle according to the internal command generated by the parsing part; and an arbitration part managing a parsing process performed by the parsing part. The arbitration part adjusts an output timing of the second control command according to the internal command generated by the parsing part in response to notification of a timing from the second control device.