Wireless Industrial Automation Control Strategy Adaptation

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Solution Overview

Problem

Traditional closed loop control systems in industrial automation require shutdowns or extensive interruptions for changes in components, and hard-wired communication links are expensive and technically challenging to replace, while wireless communications are prone to dynamic variations and disturbances.

Innovation Solution

A method and system that monitor wireless communication characteristics, such as packet loss and delay, to improve control strategies by incorporating these parameters into the control algorithm, using models like Kalman filters and rule-based systems, without adding dedicated sensors, and applying them in a control loop to adjust actuator signals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hard-wired communication links are used in traditional closed loop control systems, then system reliability and stability are improved, but any changes in component position require production shutdowns and extensive reconfiguration

Engineering Contradiction:

Improvecontrol system stabilityVSAvoidproduction continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces hard-wired mechanical communication links with wireless communication systems. The control unit communicates with sensors and actuators through wireless signals, eliminating the need for physical wiring. This allows components to be moved or repositioned without shutting down production or reconfiguring cables, thus maintaining system reliability while ensuring production continuity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If wireless communications are used to enable flexible component positioning, then production continuity is improved, but the system becomes more susceptible to dynamic variations and disturbances

Engineering Contradiction:

Improveproduction continuityVSAvoidcommunication stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where the control unit continuously monitors wireless communication quality and adjusts control signals accordingly. The system receives feedback about communication conditions and adapts its operation to maintain stability despite wireless disturbances, thus improving communication reliability while preserving production continuity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent employs error correction codes and redundancy mechanisms in the wireless communication protocol to cushion against potential transmission errors and disturbances before they affect control accuracy. This preemptive approach ensures that even when wireless signals experience dynamic variations, the control system maintains reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Measurement precision

If additional sensors are added to monitor communication quality, then measurement precision is improved, but device complexity and hardware costs increase

Engineering Contradiction:

Improvecommunication characteristic monitoringVSAvoidsystem hardware

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent makes the existing control unit multi-functional by enabling it to perform both control functions and communication quality monitoring functions. The control unit analyzes wireless signal characteristics and uses this information to adjust control signals, eliminating the need for separate dedicated sensors and reducing system complexity while maintaining measurement precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the communication monitoring function with the control function in a single integrated system. The control unit simultaneously manages actuator control and monitors wireless communication characteristics, combining multiple functions into one component to avoid increasing device complexity and hardware costs.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If wireless communication characteristics are incorporated into control algorithms, then adaptability is improved, but control system complexity increases

Engineering Contradiction:

Improvecontrol strategy flexibilityVSAvoidcontrol algorithm

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements dynamic control where the control algorithm continuously adapts to changing wireless communication conditions. The system adjusts control signals in real-time based on current communication quality, making the control strategy flexible and adaptive without requiring overly complex algorithms, as it builds upon existing control structures.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS7881816B2Method for controlling an industrial automation device

Publication Date: 2011.02.01 ABB (SCHWEIZ) AG

AI summary

A method for controlling an industrial automation device or process including a control unit, at least one actuator, and at least one device arranged for wireless communication with the control unit. The method determines characteristics of the wireless transmissions used to communicate sensor and/or actuator data to the control unit. The method, a system and a graphic interface enable a user to select a control strategy dependent on a value or values of the characteristics of the wireless communications.