Unified Control Device for Sequence and Application Program Execution

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Solution Overview

Problem

Existing control systems in factory automation require multiple dedicated devices for executing different types of programs, leading to inefficiencies and increased complexity, particularly in synchronizing control cycles between sequence and application programs.

Innovation Solution

A control device with a first program executing unit for sequence programs and a second program executing unit for application programs, both sharing a memory to synchronize instruction values and variables, allowing cooperative execution and reducing the need for redundant interlocking measures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple dedicated devices are used to execute different types of programs, then program execution reliability is improved, but device complexity and system cost increase

Engineering Contradiction:

Improveprogram execution reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the execution of sequence programs and application programs into a single control device. The CPU executes both types of programs by switching between different execution modes, eliminating the need for separate dedicated devices while maintaining execution reliability through centralized control and coordinated timing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control device is designed with multi-functional capability to execute both sequence programs (for discrete control) and application programs (for continuous control) using a single CPU. This universal execution environment allows one device to perform multiple functions that previously required separate dedicated devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If sequence program and application program are executed in different control cycles, then program execution stability is improved, but synchronization accuracy deteriorates

Engineering Contradiction:

Improveexecution stabilityVSAvoidsynchronization accuracy

Core Design Contradiction:

Stability of the object's compositionVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where the CPU monitors the execution state of both sequence and application programs, and dynamically adjusts the timing and switching between them. This feedback control ensures that both program types execute stably in different cycles while maintaining precise synchronization through real-time state coordination.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control device employs periodic execution cycles where sequence programs and application programs are alternately executed in predetermined time intervals. This periodic action pattern provides execution stability for each program type while achieving synchronization accuracy through coordinated periodic updates of shared variables and instruction values.

Inventive Principle:

Principle #19Periodic action

3Reliability

If separate execution environments are used for sequence and application programs, then program execution reliability is improved, but waiting time increases

Engineering Contradiction:

Improveexecution reliabilityVSAvoidwaiting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent combines sequence program execution and application program execution into a single integrated CPU environment. This merging allows both program types to share the same execution resources and communicate through shared variables, eliminating waiting times associated with inter-device communication while maintaining execution reliability through proper timing coordination.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If redundant interlocking measures are implemented for synchronization, then execution reliability is improved, but device complexity increases

Engineering Contradiction:

Improveexecution reliabilityVSAvoidcontrol complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates redundant interlocking measures by implementing a unified execution environment where sequence and application programs share common memory spaces and variables. This extraction removes the need for complex synchronization protocols and interlocking mechanisms that would otherwise be required between separate devices, simplifying the control system while maintaining reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10496079B2Control device and control method

Publication Date: 2019.12.03 OMRON CORP

AI summary

An environment for easily executing a plurality of types of programs in cooperation with each other is provided. A control device includes: a first program executing unit that executes a sequence program for each first control cycle and calculates a first instruction value; a second program executing unit that executes an application program which is described in codes which are sequentially interpreted and calculates a second instruction value for each first control cycle; and a shared memory configured to be accessible by both the first program executing unit and the second program executing unit. The second program executing unit executes the application program while referring to the first shared variable value stored in the shared memory in accordance with the codes described in the application program.