METHODS, APPARATUS, AND SYSTEMS FOR MONITORING AND/OR CONTROLLING DYNAMIC ENVIRONMENTS

• US 20130096697A1
• Filed: 10/05/2012
• Published: 04/18/2013
• Est. Priority Date: 10/05/2011
• Status: Active Grant

• Current Assignee: Opteon Corporation
• Original Assignee: Opteon Corporation
• Inventors: Frazer, Mark J., Hopkins, T. Eric, Schaeffer, Timothy N.
• Granted Patent: US 9,459,607 B2
• Time in Patent Office: Days
• US Class Current: 700/12
• CPC Class Codes: G05B 13/021 in which a variable is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 19/052 Linking several PLC's
• CPC Class Codes: G05B 19/054 Input/output
• CPC Class Codes: G05B 2219/1153 Scan only some I-O registers, use flags
• CPC Class Codes: G05B 2219/2214 Multicontrollers, multimicrocomputers, multiprocessing
• CPC Class Codes: G05B 2219/2231 Master slave
• CPC Class Codes: G06F 11/07 Responding to the occurrence of a fault, e.g. fault tolerance
• CPC Class Codes: G06F 11/2005 using redundant communication controllers
• CPC Class Codes: G06F 13/126 and has means for transferring I/O instructions and statuses between control unit and main processor

Abstract

A dynamic environment (e.g., an automated industrial process) has multiple conditions in response to which corresponding actions are required, and comprises various equipment, control device(s) to control the equipment, and one or more sensors to generate input signal(s) representing a monitored condition of the environment. A control system for the environment comprises a master processor and one or more co-processors, wherein the master processor configures a given co-processor to evaluate only a first subset of conditions expected to occur in the environment within a specified time period (e.g., less than a response time of the master processor), and to provide first control information representing an action to be taken if a particular condition of the first subset is satisfied. The co-processor receives the input signal(s) representing the monitored condition, processes the input signal(s) so as to determine if the particular condition of the first subset is satisfied, and provides the first control information to the control devices so as to control the equipment. Exemplary applications include dynamic environments in which machine vision techniques and/or equipment are employed.

Claims

1. A control system for monitoring and controlling a dynamic environment having a plurality of conditions in response to which a plurality of actions are required, the control system comprising:

a master processor; and

at least one co-processor communicatively coupled to the master processor,

wherein the master processor configures the at least one co-processor to;

evaluate only a first subset of the plurality of conditions; and

provide first control information representing at least one first action of the plurality of actions if at least one condition of the first subset is satisfied.

2. The control system of claim 1, wherein:

A) the dynamic environment includes;

A1) equipment to implement an automated process;

A2) at least one control device to control the equipment in response to at least one control signal; and

A3) at least one sensor to monitor the automated process and generate at least one input signal representing a monitored condition of the plurality of conditions; and

B) the at least one co-processor;

B1) receives the at least one input signal representing the monitored condition;

B2) processes the at least one input signal so as to determine if the at least one condition of the first subset is satisfied; and

B3) provides the first control information so as to generate the at least one control signal for the at least one control device if the monitored condition matches the at least one condition of the first subset.

3. The control system of claim 2, wherein in B), the at least one co-processor further:

B4) transmits a notification signal to the master processor if the at least one condition of the first subset is satisfied.

4. A machine vision system, comprising:

the control system of claim 3;

the equipment to implement the automated process in A1);

the at least one control device in A2) to control the equipment; and

the at least one sensor to monitor the automated process,

wherein;

the equipment to implement the automated process comprises;

robotics equipment; and

lighting equipment to provide controlled ambient lighting for the automated process;

the at least one control device includes a plurality of actuators coupled to the robotics equipment and/or the lighting equipment to control the robotics equipment and/or the lighting equipment;

the at least one sensor comprises at least one image acquisition device to acquire at least one image of at least a portion of the automated process; and

the control system is communicatively coupled to the at least one control device and the at least one sensor, to receive the at least one input signal generated by the at least one sensor and to control the plurality of actuators and/or the at least one image acquisition device based at least in part on the at least one control signal generated in B3).

5. The control system of claim 1, wherein the first subset of the plurality of conditions configured by the master processor for evaluation by the at least one co-processor includes only one condition.

6. The control system of claim 1, wherein the first subset of the plurality of conditions configured by the master processor for evaluation by the at least one co-processor includes multiple conditions expected to occur in the dynamic environment within a specified time period.

7. The control system of claim 6, wherein the specified time period within which the multiple conditions are expected to occur in the dynamic environment is less than a response time of the master processor.

8. The control system of claim 6, wherein the specified time period within which the multiple conditions are expected to occur in the dynamic environment is less than a worst-case response time of the master processor.

9. The control system of claim 1, wherein the master processor determines the first subset of the plurality of conditions for evaluation by the at least one co-processor based on at least one of:

a time period in which the first subset of the plurality of conditions is expected to occur in the dynamic environment;

a particular sequence in which the plurality of conditions is expected to occur in the dynamic environment;

at least one previous action taken in the dynamic environment;

a present state of the dynamic environment;

a response time of the master processor; and

at least one attribute of the at least one co-processor.

10. The control system of claim 9, wherein:

the at least one co-processor is configured to receive and process at least one input signal representing at least one monitored condition of the plurality of conditions;

the at least one co-processor is configured to output at least one output signal corresponding to the first control information representing the at least one first action of the plurality of actions; and

the at least one attribute of the at least one co-processor comprises at least one of;

a functioning status of the at least one co-processor;

a first number of the at least one input signal processed by the at least one co-processor;

a first type of the at least one input signal processed by the at least one co-processor;

a second number of the at least one output signal processed by the at least one co-processor; and

a second type of the at least one output signal processed by the at least one co-processor.

11. The control system of claim 1, wherein the master processor determines the first subset of the plurality of conditions for evaluation by the at least one co-processor based on at least one compiled executable instruction representing at least one source code wait statement, wherein the at least one source code wait statement specifies the at least one condition of the first subset of the plurality of conditions and the at least one first action of the plurality of actions.

12. The control system of claim 1, wherein:

the at least one co-processor is configured to evaluate a fixed maximum number of conditions;

the maximum number of conditions is based at least in part on a maximum permissible latency defined by a required response time in the dynamic environment for providing the first control information if the at least one condition of the first subset is satisfied; and

the first subset of the plurality of conditions configured by the master processor for evaluation by the at least one co-processor includes less than or equal to the maximum number of conditions.

13. The control system of claim 1, wherein the at least one co-processor includes at least a first co-processor and a second co-processor, and wherein:

the master processor configures the first co-processor to evaluate only the first subset of the plurality of conditions and to provide the first control information representing the at least one first action of the plurality of actions if the at least one condition of the first subset is satisfied; and

the master processor configures the second co-processor to evaluate only a second subset of the plurality of conditions and to provide second control information representing at least one second action of the plurality of actions if at least one condition of the second subset is satisfied.

14. The control system of claim 13, wherein the first subset of the plurality of conditions and the second subset of the plurality of conditions both include at least one common condition for evaluation by the first co-processor and the second co-processor, respectively.

15. The control system of claim 13, wherein:

a monitored condition of the plurality of conditions is represented by at least one input signal;

at least the first co-processor and the second co-processor simultaneously receive the at least one input signal representing the monitored condition; and

the first co-processor and the second co-processor independently evaluate the first subset and the second subset of the plurality of conditions, respectively, based at least in part on the at least one input signal.

16. The control system of claim 13, wherein the second subset of the plurality of conditions evaluated by the second co-processor includes at least one second subset condition indicating whether or not the at least one condition of the first subset is satisfied.

17. The control system of claim 1, wherein:

at a first time, the master processor configures the at least one co-processor to evaluate only the first subset of the plurality of conditions and to provide the first control information representing the at least one first action of the plurality of actions if the at least one condition of the first subset is satisfied; and

at a second time, the master processor reconfigures the at least one co-processor to evaluate only a second subset of the plurality of conditions and to provide second control information representing at least one second action of the plurality of actions if at least one condition of the second subset is satisfied.

18. The control system of claim 17, wherein the master processor determines the second subset of the plurality of conditions for evaluation by the at least one co-processor at the second time based at least in part on whether or not the at least one condition of the first subset is satisfied.

19. The control system of claim 17, wherein the master processor determines the second subset of the plurality of conditions for evaluation by the at least one co-processor based on at least one of:

a time period in which the second subset of the plurality of conditions is expected to occur in the dynamic environment;

a particular sequence in which the plurality of conditions is expected to occur in the dynamic environment;

a present state of the dynamic environment;

at least one previous action taken in the dynamic environment;

the response time of the master processor; and

at least one attribute of the at least one co-processor.

20. The control system of claim 19, wherein:

the at least one co-processor is configured to receive and process at least one input signal representing at least one monitored condition of the plurality of conditions;

the at least one co-processor is configured to output at least one output signal corresponding to the second control information representing the at least one second action of the plurality of actions; and

the at least one attribute of the at least one co-processor comprises at least one of;

a functioning status of the at least one co-processor;

a first number of the at least one input signal processed by the at least one co-processor;

a first type of the at least one input signal processed by the at least one co-processor;

a second number of the at least one output signal processed by the at least one co-processor; and

a second type of the at least one output signal processed by the at least one co-processor.

21. The control system of claim 17, wherein the master processor determines the second subset of the plurality of conditions for evaluation by the at least one co-processor based on at least one compiled executable instruction representing at least one source code wait statement, wherein the at least one source code wait statement specifies the at least one condition of the second subset of the plurality of conditions and the at least one second action of the plurality of actions.

22. The control system of claim 1, wherein a monitored condition of the plurality of conditions is represented by at least one input signal, and wherein the at least one co-processor comprises:

at least one input interface to receive the at least one input signal representing the monitored condition and/or first configuration information from the master processor relating to evaluation of the first subset of conditions;

a dedicated memory to store at least the first configuration information received from the master processor;

at least one output interface to provide the first control information representing the at least one first action of the plurality of actions; and

at least one controller, communicatively coupled to the at least one input interface, the dedicated memory, and the at least one output interface, wherein the at least one controller is configured to;

process the at least one input signal based at least in part on the first configuration information received from the master processor so as to determine if the at least one condition of the first subset is satisfied; and

control the at least one output interface so as to provide the first control information if the at least one condition of the first subset is satisfied.

23. The control system of claim 22, wherein the at least one controller of the at least one co-processor further is configured to control the at least one output interface so as to transmit a notification signal to the master processor if the at least one condition of the first subset is satisfied.

24. The control system of claim 22, wherein:

the at least one input signal includes a plurality of input signals, wherein respective values of the plurality of input signals at a given time represent the monitored condition of the plurality of conditions; and

the at least one input interface of the at least one co-processor is configured to receive the plurality of input signals.

25. The control system of claim 24, wherein the respective values of the plurality of input signals comprise at least one of:

a plurality of real-time values representing the monitored condition;

a plurality of latched values representing the monitored condition;

at least one multi-bit digital value representing the monitored condition; and

a plurality of binary values respectively representing different sensed parameters constituting the monitored condition.

26. The control system of claim 22, wherein:

the first configuration information received from the master controller by the at least one co-processor includes a first executable program codifying the first subset of conditions for evaluation by the at least one co-processor;

the at least one input interface of the at least one co-processor is configured to receive the first executable program;

the dedicated memory of the at least one co-processor stores the first executable program when received by the at least one input interface; and

the at least one controller of the at least one co-processor includes a central processing unit to execute the first executable program so as to evaluate the first subset of conditions based at least in part on the at least one input signal representing the monitored condition.

27. The control system of claim 22, wherein:

the first configuration information received from the master controller by the at least one co-processor includes at least one condition/action pair representing the first subset of conditions for evaluation by the at least one co-processor;

the at least one input interface of the at least one co-processor is configured to receive the at least one condition/action pair;

the dedicated memory of the at least one co-processor stores the at least one condition/action pair when received by the at least one input interface; and

the at least one controller of the at least one co-processor includes digital logic circuitry to evaluate the at least one condition/action pair based at least in part on the at least one input signal representing the monitored condition.

28. The control system of claim 27, wherein:

A) the dedicated memory includes at least one register to store the at least one condition/action pair;

B) the at least one condition/action pair includes a first number of bits having respective values representing a particular condition of the first subset of conditions to be evaluated, and a second number of bits having respective values representing a corresponding action to be taken if the particular condition is satisfied; and

C) the digital logic circuitry includes;

C1) at least one comparator to;

compare the respective values of the first number of bits representing the particular condition and at least one value of the at least one input signal representing the monitored condition; and

provide a match signal if the particular condition matches the monitored condition; and

C2) at least one gate, coupled to the at least one register of the dedicated memory, and coupled to the comparator to receive the match signal, to provide to the at least one output interface, if the match signal is asserted by the comparator, the second number of bits representing the corresponding action to be taken,

wherein the at least one output interface provides the second number of bits as the first control information.

29. The control system of claim 28, wherein the at least one output interface provides the match signal as a notification signal to the master processor to indicate that the particular condition matches the monitored condition.

30. The control system of claim 28, wherein:

the dedicated memory is configured to store a fixed maximum number of condition/action pairs; and

at least one of the maximum number of condition/action pairs and the size of the at least one register is based at least in part on a maximum permissible latency defined by a required response time in the dynamic environment for providing the first control information if the at least one condition of the first subset is satisfied.

31. The control system of claim 28, wherein:

the dedicated memory includes a plurality of registers to store a plurality of condition/action pairs, each condition/action pair of the plurality of condition action pairs including the first number of bits having respective values representing a particular condition of the first subset of conditions to be evaluated, and the second number of bits having respective values representing the corresponding action to be taken if the particular condition is satisfied; and

the digital logic circuitry further comprises scanning circuitry to successively couple the at least one comparator and the at least one gate to the plurality of registers of the dedicated memory to sequentially process the plurality of condition/action pairs.

32. In a system comprising a master processor and at least one co-processor communicatively coupled to the master processor, a method for monitoring and controlling a dynamic environment having a plurality of conditions in response to which a plurality of actions are required, the method comprising:

A) determining, via the master processor, a first subset of the plurality of conditions expected to occur in the dynamic environment within a specified time period that is less than a response time of the master processor; and

B) evaluating, via the at least one co-processor, the first subset of the plurality of conditions determined in A) so as to provide first control information representing at least one first action of the plurality of actions if at least one condition of the first subset is satisfied.

33. The method of claim 32, further comprising:

transmitting, from the at least one co-processor to the master processor, a notification signal if the at least one condition of the first subset is satisfied.

34. The method of claim 32, wherein in A), the a specified time period is less than a worst-case response time of the master processor.

35. The method of claim 32, wherein A) comprises determining the first subset of the plurality of conditions based on at least one of:

a particular sequence in which the plurality of conditions is expected to occur in the dynamic environment;

at least one previous action taken in the dynamic environment;

a present state of the dynamic environment; and

at least one attribute of the at least one co-processor.

36. The method of claim 35, wherein:

the at least one co-processor is configured to receive and process at least one input signal representing at least one monitored condition of the plurality of conditions;

the at least one co-processor is configured to output at least one output signal corresponding to the first control information representing the at least one first action of the plurality of actions; and

the at least one attribute of the at least one co-processor comprises at least one of;

a functioning status of the at least one co-processor;

a first number of the at least one input signal processed by the at least one co-processor;

a first type of the at least one input signal processed by the at least one co-processor;

a second number of the at least one output signal processed by the at least one co-processor; and

a second type of the at least one output signal processed by the at least one co-processor.

37. The method of claim 32, wherein A) comprises determining the first subset of the plurality of conditions based on execution by the master processor of at least one compiled executable instruction representing at least one source code wait statement, wherein the at least one source code wait statement specifies the at least one condition of the first subset of the plurality of conditions and the at least one first action of the plurality of actions.

38. The method of claim 32, wherein A) further comprises:

determining a fixed maximum number of conditions for evaluation by the at least one co-processor based on the response time of the master processor,

wherein the first subset of the plurality of conditions includes less than or equal to the maximum number of conditions.

39. The method of claim 32, wherein the at least one co-processor includes at least a first co-processor and a second co-processor, and wherein:

B) comprises evaluating, via the first co-processor, the first subset of the plurality of conditions determined in A) so as to provide the first control information representing the at least one first action of the plurality of actions if at least one condition of the first subset is satisfied, and wherein the method further comprises;

C) determining, via the master processor, a second subset of the plurality of conditions expected to occur in the dynamic environment within the specified time period; and

D) evaluating, via the second co-processor, the second subset of the plurality of conditions determined in C) so as to provide second control information representing at least one second action of the plurality of actions if at least one condition of the second subset is satisfied.

40. The method of claim 39, wherein the second subset of the plurality of conditions determined in C) includes at least one second subset condition indicating whether or not the at least one condition of the first subset is satisfied.

41. The method of claim 39, wherein:

a monitored condition of the plurality of conditions is represented by at least one input signal;

at least the first co-processor and the second co-processor simultaneously receive the at least one input signal representing the monitored condition; and

the first co-processor and the second co-processor independently evaluate the first subset and the second subset of the plurality of conditions, respectively, based at least in part on the at least one input signal.

42. The method of claim 32, further comprising, at a time after execution of B):

C) determining, via the master processor, a second subset of the plurality of conditions expected to occur in the dynamic environment within the specified time period; and

D) evaluating, via the at least one co-processor, the second subset of the plurality of conditions determined in C) so as to provide second control information representing at least one second action of the plurality of actions if at least one condition of the second subset is satisfied.

43. The method of claim 42, wherein C) comprises:

determining the second subset of the plurality of conditions based at least in part on whether or not the at least one condition of the first subset is satisfied in B).

44. The method of claim 32, wherein:

a monitored condition of the plurality of conditions is represented by a plurality of input signals, wherein respective values of the plurality of input signals at a given time represent the monitored condition of the plurality of conditions; and

the respective values of the plurality of input signals comprise at least one of;

a plurality of real-time values representing the monitored condition;

a plurality of latched values representing the monitored condition;

at least one multi-bit digital value representing the monitored condition; and

a plurality of binary values respectively representing different sensed parameters constituting the monitored condition.

45. A control system for monitoring and controlling a dynamic environment having a plurality of conditions in response to which a plurality of actions are required, the dynamic environment comprising equipment to implement an automated process, at least one control device to control the equipment in response to at least one control signal, and at least one sensor to monitor the automated process and generate at least one input signal representing a monitored condition of the plurality of conditions, the control system comprising:

a master processor; and

at least one co-processor communicatively coupled to the master processor,

wherein;

the master processor configures the at least one co-processor to;

evaluate only a first subset of the plurality of conditions expected to occur in the dynamic environment within a specified time period that is less than a response time of the master processor; and

provide first control information representing at least one first action of the plurality of actions if at least one condition of the first subset is satisfied; and

the at least one co-processor;

receives the at least one input signal representing the monitored condition;

processes the at least one input signal so as to determine if the at least one condition of the first subset is satisfied; and

provides the first control information so as to generate the at least one control signal for the at least one control device if the monitored condition matches the at least one condition of the first subset.

46. A machine vision system, comprising:

the control system of claim 45;

the equipment to implement the automated process;

the at least one control device to control the equipment; and

the at least one sensor to monitor the automated process,

wherein;

the equipment to implement the automated process comprises;

robotics equipment; and

lighting equipment to provide controlled ambient lighting for the automated process;

the at least one control device includes a plurality of actuators coupled to the robotics equipment and/or the lighting equipment to control the robotics equipment and/or the lighting equipment;

the at least one sensor comprises at least one image acquisition device to acquire at least one image of at least a portion of the automated process; and

the control system is communicatively coupled to the at least one control device and the at least one sensor, to receive the at least one input signal generated by the at least one sensor and to control the plurality of actuators and/or the at least one image acquisition device based at least in part on the at least one control signal for the at least one control device.