Unified Control Execution for Synchronized IEC and Application Programs
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Solution Overview
Problem
Current control systems in factory automation face challenges in synchronizing the execution of different types of programs, such as IEC programs and application programs, which leads to inefficiencies and delays in control cycles, particularly in CNC machining and robot assembly systems.
Innovation Solution
A control device with a storage unit, execution processing unit, interpreter, command value computation unit, and output unit is designed to execute IEC programs and application programs in synchronization, using intermediate code generated by the interpreter to compute command values at every control cycle, allowing for flexible execution and data synchronization across multiple control applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple dedicated control devices are used to handle different program types, then each program type can be executed with dedicated optimization, but the system complexity and number of devices increase
Solution Approach 1:
The patent merges multiple dedicated control devices into a single control device that can execute both IEC programs (scanned as a whole) and application programs (sequentially executed). The control device includes an execution processing unit for IEC programs and a command value computation unit for application programs, allowing both program types to be handled by one integrated system rather than requiring separate dedicated devices.
Solution Approach 2:
The control device achieves multi-functionality by incorporating both an execution processing unit that scans IEC programs as a whole and a command value computation unit that sequentially executes application programs. This universal control device can adapt to different program execution formats and control requirements, replacing multiple specialized devices with one versatile unit.
2Device complexity
If IEC programs and application programs are executed in the same control device, then device integration is achieved, but synchronization of execution becomes complex and may cause delays
Solution Approach 1:
The control device segments the execution process into distinct phases: the execution processing unit scans the entire IEC program as a whole at each control cycle, while the command value computation unit sequentially executes application programs and generates intermediate codes. This segmentation allows each unit to operate independently with its own execution format, avoiding conflicts and synchronization delays while maintaining integration within a single device.
Solution Approach 2:
The patent introduces intermediate codes as a mediator between the sequential execution of application programs and the cyclic scanning of IEC programs. The command value computation unit generates intermediate codes from application programs, which are then processed during the IEC program scan cycle. This intermediary mechanism enables synchronized execution of both program types without direct conflict, as the intermediate codes bridge the different execution formats.
3Adaptability or versatility
If sequential execution format is used for application programs, then complex control logic can be implemented, but execution speed and real-time performance may be reduced
Solution Approach 1:
The command value computation unit performs preliminary action by pre-computing command values and generating intermediate codes during the control cycle, before the IEC program scan is completed. This allows sequential application programs to be processed in advance, and their results are ready for immediate use, improving execution speed without sacrificing the complex control logic capability of sequential formatting.
Data Source
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AI summary
The present disclosure meets demand to realize control computations according to programs having different execution formats by a single control device (100). The control device (100) includes a storage unit (108) storing a first program (30) to be scanned as a whole for each execution and a second program (32) that is sequentially executed, an execution processing unit (150) computing a first command value by executing the first program (30) at every predetermined control cycle, an interpreter (168) interpreting at least a part of the second program (32) and generating an intermediate code (34), a command value computation unit (160) computing a second command value at every control cycle according to the intermediate code (34) generated in advance by the interpreter (168), and an output unit (180) outputting the first command value computed by the execution processing unit (150) and the second command value computed by the command value computation unit (160) at every control cycle.