Hardware architecture and method for distributed machine control

A method for controlling a first and a second actuator, comprising:

• storing a first and a second program of instructions on a host computer;
• linking the host computer to a first and a second control module;
• coupling the first control module to the first actuator and the second control module to the second actuator;
• retrieving the first program of instructions from the host computer and loading it into the first control module;
• retrieving the second program of instructions from the host computer and loading it into the second control module;
• controlling the first actuator with the first control module;
• and
• controlling the second actuator with the second module.

A method for distributed machine control, comprising:

• storing a first and a second program of instructions on a host computer;
• linking the host computer to a first control module;
• linking the first control module to a second control module;
• coupling the first control module to a first actuator and the second control module to a second actuator;
• retrieving the first program of instructions from the host computer and loading it into the first control module;
• retrieving the second program of instructions from the host computer and loading it into the second control module;
• controlling the first actuator with the first control module;
• and
• controlling the second actuator with the second module.

A method for distributed machine control, comprising:

• controlling a first actuator with a first control module, said first module including a first processor carrying out a program of instructions and generating a first set of signals for controlling said first actuator;
• controlling a second actuator with a second control module, said second module including a second processor carrying out a program of instructions and generating a second set of signals for controlling said second actuator;
• linking said first set of signals through a first error current block disposed in said first module to said first actuator, said first error current block receiving and transmitting an error current loop signal and interrupting said first set of signals if said error current loop signal is interrupted;
• linking said second set of signals through a second error current block disposed in said second module to said second actuator, said second error current block receiving and transmitting said error current loop signal and interrupting said second set of signals if said error current loop signal is interrupted;
• detecting an error condition;
• and
• interrupting said error current loop signal upon detection of said error condition.

A control module for controlling an actuator, said control module comprising:

• a communications/processor unit including
• a component specifying a unique identification for the communications/processor module;
• a processor;
• a non-volatile memory providing a bootstrap load program of instructions for the processor;
• and
• a volatile program memory for storing a program of instructions for controlling the processor;
• and
• a function unit for driving the actuator, said communications/processor unit electrically coupled to said function unit.

An apparatus for controlling an actuator, comprising:

• a host computer;
• means for storing a program of instructions on the host computer;
• means for linking the host computer to a control module;
• means for coupling the control module to the actuator;
• means for retrieving the program of instructions from the host computer and loading it into the control module;
• and
• means for controlling the actuator with the control modulator.

An apparatus for controlling a first and a second actuator, comprising:

• a host computer;
• means for storing a first and a second program of instructions on the host computer;
• means for linking the host computer to a first and a second control module;
• means for coupling the first control module to the first actuator and the second control module to the second actuator;
• means for retrieving the first program of instructions from the host computer and loading it into the first control module;
• means for retrieving the second program of instructions from the host computer and loading it into the second control module;
• means for controlling the first actuator with the first control module;
• and
• means for controlling the second actuator with the second module.

An apparatus for distributed machine control, comprising:

• a host computer;
• means for storing a first and a second program of instructions on the host computer;
• means for linking the host computer to a first control module;
• means for linking the first control module to a second control module;
• means for coupling the first control module to a first actuator and the second control module to a second actuator;
• means for retrieving the first program of instructions from the host computer and loading it into the first control module;
• means for retrieving the second program of instructions from the host computer and loading it into the second control module;
• means for controlling the first actuator with the first control module;
• and
• means for controlling the second actuator with the second module.

An apparatus for distributed machine control, comprising:

• means for controlling a first actuator with a first control module, said first module including a first processor carrying out a program of instructions and generating a first set of signals for controlling said first actuator;
• means for controlling a second actuator with a second control module, said second module including a second processor carrying out a program of instructions and generating a second set of signals for controlling said second actuator;
• means for linking said first set of signals through a first error current block disposed in said first module to said first actuator, said first error current block receiving and transmitting an error current loop signal and interrupting said first set of signals if said error current loop signal is interrupted;
• means for linking said second set of signals through a second error current block disposed in said second module to said second actuator, said second error current block receiving and transmitting said error current loop signal and interrupting said second set of signals if said error current loop signal is interrupted;
• means for detecting an error condition;
• and
• means for interrupting said error current loop signal upon detection of said error condition.

A method for controlling an actuator, comprising:

• storing a program of instructions on a host computer;
• linking the host computer to a control module;
• coupling the control module to the actuator;
• retrieving the program of instructions from the host computer and loading it into the control module;
• controlling the actuator with the control modulator;
• sending state information reflecting a state of the control module from the control module to the host computer repeatedly at fixed time intervals;
• and
• storing the state information in memory of the host computer between said fixed time intervals.

An apparatus for controlling an actuator, comprising:

• a host computer;
• means for storing a program of instructions on the host computer;
• a control module;
• means for linking the host computer to said control module;
• means for coupling said control module to the actuator;
• means for retrieving the program of instructions from the host computer and loading it into said control module;
• means for controlling the actuator with said control modulator;
• means for sending state information reflecting a state of said control module from said control module to the host computer repeatedly at fixed time intervals;
• and
• means for storing the state information in memory of the host computer between said fixed time intervals.

A method for controlling an actuator in a machine having at least one control module for providing control signals to the actuator and a host computer for controlling the control module, said method comprising:

• linking the host computer with the control module via a high-speed data bus;
• coupling the control module to the actuator;
• maintaining and updating a first set of data at the control module;
• transmitting said first set of data to the host computer periodically at fixed intervals of time without polling;
• maintaining and updating a second set of data at the host computer;
• and
• transmitting said second set of data to the control module periodically at fixed intervals of time without polling.

An apparatus for controlling an actuator in a machine having at least one control module for providing control signals to the actuator and a host computer for controlling the control module, said apparatus comprising:

• means for linking the host computer with the control module via a high-speed data bus;
• means for coupling the control module to the actuator;
• means for maintaining and updating a first set of data at the control module;
• means for transmitting said first set of data to the host computer periodically at fixed intervals of time without polling;
• means for maintaining and updating a second set of data at the host computer;
• and
• means for transmitting said second set of data to the control module periodically at fixed intervals of time without polling.

A method for sensing and responding to a condition sensed by a sensor coupled to a control module, the control module coupled to a host computer, said method comprising:

• linking the host computer with the control module via a high-speed data bus;
• sensing a condition with the sensor;
• reporting the condition to the control module;
• maintaining and updating a first set of data dependent upon the condition at the control module;
• and
• transmitting said first set of data to the host computer periodically at fixed intervals of time without polling.

An apparatus for sensing and responding to a condition sensed by a sensor coupled to a control module, the control module coupled to a host computer, said apparatus comprising:

• means for linking the host computer with the control module via a high-speed data bus;
• means for sensing a condition with the sensor;
• means for reporting the condition to the control module;
• means for maintaining and updating a first set of data dependent upon the condition at the control module;
• and
• means for transmitting said first set of data to the host computer periodically at fixed intervals of time without polling.