Synchronous Automation Control With Protocol Lag Compensation
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Solution Overview
Problem
Modern manufacturing and automation systems face complexity in integrating products from different manufacturers due to varying communication protocols and latency issues, making it difficult to coordinate activities between automation systems from different vendors.
Innovation Solution
A method and system for managing automation systems involving synchronous elements, which includes determining a master signal, communication protocol, and compensation profiles to account for lag time and characteristics, allowing for synchronization and efficient operation across different vendors' equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different communication protocols are used from various manufacturers, then hardware interchangeability and system integration are improved, but communication latency and synchronization complexity increase
Solution Approach 1:
The patent introduces a master signal as an intermediary that coordinates multiple synchronous elements from different manufacturers. The master signal acts as a mediator that translates and synchronizes communications across different protocols, reducing latency by providing a centralized coordination mechanism rather than requiring direct peer-to-peer protocol conversion between all elements.
Solution Approach 2:
The system performs preliminary determination of lag times for each synchronous element based on their characteristics and communication protocols. Compensation profiles are pre-calculated and applied to anticipate and correct synchronization delays before they affect system operation, thereby reducing actual communication latency impacts.
2Adaptability or versatility
If communication protocol conversion is implemented using industrial computers, then hardware interchangeability is improved, but system complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts the protocol conversion functionality from complex industrial computers and embeds it directly into the controller system. The master signal mechanism and compensation profiles are integrated into the control architecture, separating the synchronization logic from heavy protocol conversion hardware, thereby reducing overall system complexity while maintaining protocol compatibility.
Solution Approach 2:
The master signal system serves multiple functions simultaneously: it provides synchronization, coordinates protocol conversions, manages timing compensation, and enables hardware interchangeability. This multi-functional approach eliminates the need for separate dedicated protocol conversion hardware, reducing system complexity.
3Productivity
If real-time coordination between automation systems is implemented, then productivity is improved, but synchronization precision and latency management become more difficult
Solution Approach 1:
The system implements feedback through compensation profiles that are determined based on actual lag time measurements for each synchronous element. The master signal mechanism continuously monitors and adjusts timing compensations to maintain synchronization precision, providing real-time feedback loops that preserve both productivity and precision.
Solution Approach 2:
The patent changes timing parameters by applying predetermined lag time compensations to each synchronous element's operation. By adjusting these temporal parameters based on element characteristics and communication protocols, the system achieves precise synchronization while maintaining high productivity through coordinated real-time operation.
Data Source
AI summary
A method for managing an automation system involving a plurality of synchronous elements, the method including: designating a master signal for controlling the plurality of synchronous elements; determining a communication protocol for communicating the master signal to the plurality of synchronous elements; determining a compensation profile for each of the plurality of synchronous elements based on the communication protocol and characteristics of each of the plurality of synchronous elements; and utilizing the compensation profile in the control of the automation system. A system for managing an automation system involving at least two synchronous elements, the system including: a first controller for controlling a first synchronous element; a second controller for controlling at least a second synchronous element; a configuration module for configuring at least the second synchronous element; a memory storing instructions that, when executed by the second controller, cause the second controller to perform the method above.