MECHATROLINK-III-based coupler system and communication method

Abstract

The invention relates to a coupler system based on MECHATROLINK-III and a communication method, the system comprises a MECHATROLINK-III master station, a MECHATROLINK-III special cable, a MECHATROLINK-III coupler and a plurality of plug-in IO modules, the MECHATROLINK-III coupler is used for managing all the plug-in IO modules in a slot so as to carry out ordered IO input and output, and the plug-in IO modules are used for carrying out plug-in IO input and output. The communication module is used for carrying out communication interaction between IO data of the whole coupler system and a MECHATROLINK-III master station; and the MECHATROLINK-III coupler is integrated with a plurality of control units or execution units. The MECHATROLINK-III coupler has the advantages that the communication stability and the communication efficiency are guaranteed while the cost of the MECHATROLINK-III coupler system is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of communication couplers, and in particular to a coupler system and method based on MECHATROLINK-III. Background Art

[0002] MECHATROLINK-Ⅲ is an open communication protocol for industrial automation. It is high-speed and low-cost, and is used for communication between device-level control systems and distributed I / O. It has been applied in manufacturing automation, process industry automation, buildings, transportation, and electricity.

[0003] Currently, the only devices on the market that support the MECHATROLINK-Ⅲ industrial communication protocol are IO-type devices, which only support a small number of fixed-point analog or digital quantities, such as 8DI, 32DO, 4AI or 4AO IO-type devices. When users want to use more analog or digital quantities, they can only use multiple IO-type devices for connection. This not only increases the number and cost of IO-type devices, but also because each IO-type device requires a dedicated cable to communicate with the MECHATROLINK-Ⅲ master station, resulting in complicated wiring at the production site and extremely difficult troubleshooting of communication line faults. In addition, the existing MECHATROLINK-Ⅲ coupler system is prone to data synchronization instability and communication delays during high-speed communication, affecting the efficiency and quality of robot collaborative operations. Summary of the invention

[0004] In order to reduce the cost of the MECHATROLINK-Ⅲ coupler system while ensuring the stability and efficiency of communication, the present application provides a coupler system and a communication method based on MECHATROLINK-Ⅲ.

[0005] In the first aspect, the above-mentioned invention objective of the present application is achieved through the following technical solutions: A coupler system based on MECHATROLINK-Ⅲ, the coupler system comprising a MECHATROLINK-Ⅲ master station, a MECHATROLINK-Ⅲ dedicated cable, a MECHATROLINK-Ⅲ coupler and a plurality of plug-in IO modules, the MECHATROLINK-Ⅲ coupler being used to manage all the plug-in IO modules in the slots to perform orderly IO input and output, and to undertake the communication interaction between the IO data of the entire coupler system and the MECHATROLINK-Ⅲ master station; The MECHATROLINK-Ⅲ coupler is integrated with a plurality of control units or execution units.

[0006] By adopting the above technical solution, in modern industrial automation control systems, with the increase in the number and complexity of equipment, the traditional IO (input and output) management method faces problems such as insufficient scalability, low communication efficiency and high system maintenance costs. In particular, when using the MECHATROLINK-Ⅲ protocol for large-scale equipment interconnection, it is difficult to efficiently manage many plug-in IO modules to ensure orderly transmission and real-time synchronization of data. Therefore, the complex multiple MECHATROLINK-Ⅲ dedicated cables are simplified to one MECHATROLINK-Ⅲ dedicated cable, which is convenient for troubleshooting communication line faults, and multiple IO-type devices are changed to plug-in IO modules to reduce the operation failures of automated production lines caused by cable connection errors. By integrating the control unit and the execution unit in the MECHATROLINK-Ⅲ coupler, efficient management and orderly control of all plug-in IO modules in the slot are achieved, and the connection with MECHATROLIN is optimized. The communication interaction mechanism of the K-Ⅲ master station has greatly improved the overall performance and reliability of the system. A system architecture is constructed with the MECHATROLINK-Ⅲ master station as the core, which is connected to the MECHATROLINK-Ⅲ coupler through a dedicated cable. Multiple control units are integrated inside the coupler to manage and schedule the plug-in IO modules in each slot. The MECHATROLINK-Ⅲ coupler uses its internal control unit to monitor and dynamically configure each plug-in IO module in the slot in real time to ensure that each module can perform IO operations in accordance with the predetermined order and rules. It also uses efficient communication protocols and scheduling algorithms to optimize the data transmission process between the MECHATROLINK-Ⅲ coupler and the master station. Through intelligent data compression and decompression technology, the data transmission volume is reduced and the communication efficiency is improved. In addition, according to the real-time load of the system, the communication bandwidth allocated to each plug-in IO module is dynamically adjusted to ensure that key data can be transmitted first while avoiding network congestion.

[0007] In a preferred example, the present application can be further configured as follows: the coupler system further includes: Data synchronization module, used to achieve time synchronization and traffic scheduling; A data redundancy check module is used to perform a cyclic redundancy check on the data packet; A dynamic bandwidth allocation module, for real-time monitoring and dynamically adjusting bandwidth allocation of the MECHATROLINK-III coupler according to operational requirements; Predictive data synchronization module, which is used to predict data synchronization needs by analyzing historical data and current status, and schedule resources in advance; The intelligent monitoring and feedback module is used to monitor the stability and synchronization of data transmission in real time, and trigger retransmission or error correction processes when an abnormality is found.

[0008] By adopting the above technical solutions, due to the increasing requirements of industrial automation control systems for real-time, reliability and data integrity, the traditional MECHATROLINK-Ⅲ coupler system often faces problems such as inaccurate time synchronization, error-prone data transmission, unreasonable bandwidth allocation and delayed data synchronization response when facing complex and changeable operating environments, resulting in production line shutdowns and failures, increasing the company's operating costs. Therefore, by introducing time-sensitive network (TSN) technology in the data synchronization module, high-precision time synchronization between nodes in the system is achieved to ensure the real-time and synchronization of data transmission. At the same time, through the traffic scheduling mechanism, the data transmission path is optimized, network delays are reduced, and a circular The redundancy check (CRC) algorithm verifies the transmitted data packets to ensure the integrity and accuracy of the data. Once a data error is found, the retransmission mechanism is immediately triggered to ensure reliable data transmission. The system's operating requirements and bandwidth usage are monitored in real time. The bandwidth allocation of each node is dynamically adjusted according to actual needs. More bandwidth is allocated to key nodes during peak hours to ensure priority transmission of key data while avoiding network congestion. Big data analysis technology is used to analyze historical data and current system status to predict future data synchronization needs. By scheduling resources in advance, the data synchronization process is optimized to reduce waiting time and synchronization delay. Intelligent monitoring algorithms are integrated to monitor the stability and synchronization of data transmission in real time. Once an abnormality is found, the corresponding processing mechanism is immediately triggered, such as retransmission, error correction or fault warning. At the same time, through the feedback mechanism, system parameters and algorithms are continuously optimized to improve the overall performance and stability of the system.

[0009] In a preferred example, the present application can be further configured as follows: the dynamic bandwidth allocation module is used to monitor the communication load between the MECHATROLINK-Ⅲ master station and each of the plug-in IO modules in real time, and According to the communication load, determine the importance and urgency of the communication data, analyze and determine the priority of the data, and Based on the communication load condition and the priority of the data, the communication bandwidth allocated to each of the plug-in IO modules is dynamically adjusted.

[0010] By adopting the above technical solution, since the MECHATROLINK-Ⅲ master station in the industrial automation control system needs to frequently exchange data with multiple plug-in IO modules, the communication load between these modules is often unbalanced, and the importance and urgency of the data are also different. The traditional bandwidth allocation method often adopts a static or fixed strategy, which cannot be dynamically adjusted according to the real-time communication load and data priority, resulting in delayed transmission of key data due to insufficient bandwidth, affecting production efficiency and system stability. Therefore, through the dynamic bandwidth allocation module, the module can monitor the communication load between the MECHATROLINK-Ⅲ master station and each plug-in IO module in real time, and dynamically adjust the bandwidth allocation according to the importance and urgency of the data to ensure that key data is transmitted first. The dynamic bandwidth allocation module first monitors the network The communication load between the MECHATROLINK-Ⅲ master station and each plug-in IO module is obtained in real time based on indicators such as network traffic and response time. According to preset rules or algorithms, the communication data is classified and prioritized, and factors such as data content, source, purpose, and real-time requirements are analyzed to determine critical and urgent data that needs to be transmitted first. Based on the communication load and data priority, the dynamic bandwidth allocation module will automatically adjust the communication bandwidth allocated to each plug-in IO module. When the communication load is high, the transmission bandwidth of critical data is prioritized; when the load is low, bandwidth resources are reasonably allocated according to actual needs to avoid waste. In addition, the dynamic bandwidth allocation module will continuously collect feedback information according to the actual operation of the system, optimize and adjust the bandwidth allocation strategy to adapt to the changing communication load and data requirements.

[0011] In a preferred example, the present application can be further configured as follows: the predictive data synchronization module is used to monitor the operating status data of the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module in real time, identify abnormal data, and Analyze the abnormal data using machine learning algorithms to predict the type and time of failure, and According to the fault type and time, a predefined fast recovery strategy is triggered.

[0012] By adopting the above technical solutions, in order to deal with the sudden failures that may occur in the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module in the industrial automation control system, the traditional fault handling mechanism often relies on post-event response, that is, diagnosis and repair after the failure occurs. This method not only has a slow response speed, but may also have a great impact on production. In addition, due to the lack of real-time monitoring and prediction capabilities of the system operation status, it is difficult for system maintenance personnel to discover and prevent potential failures in advance.

[0013] Core solution idea: In order to detect and prevent system failures in advance, the predictive data synchronization module monitors the system operation status data in real time, uses machine learning algorithms to analyze abnormal data, predicts the type and time of failure, and triggers predefined rapid recovery strategies accordingly, thereby achieving early warning and rapid response to failures. The predictive data synchronization module first obtains the operation status data of the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module in real time through the data acquisition interface, including but not limited to temperature, voltage, current and communication status, etc., pre-processes the collected operation status data, and identifies abnormal data, namely data cleaning, denoising and normalization. ization and other steps to ensure the accuracy and comparability of the data, use machine learning algorithms (such as support vector machines, random forests and neural networks, etc.) to analyze abnormal data, explore the failure modes and laws behind the data, predict possible failure types and times, and then trigger predefined rapid recovery strategies based on the prediction results, such as adjusting system parameters, switching backup equipment, and sending early warning notifications to maintenance personnel, so as to minimize the impact of failures on production; the predictive data synchronization module will also continuously collect feedback information based on the actual fault handling effect, and continuously optimize and improve the machine learning model to improve the accuracy of fault prediction and the effectiveness of rapid recovery strategies.

[0014] In a preferred example, the present application can be further configured as follows: the data synchronization module is used to control the time deviation between the MECHATROLINK-Ⅲ master station, the MECHATROLINK-Ⅲ coupler and the plug-in IO module to be within a predetermined range, and Scheduling communication traffic according to the real-time nature of data transmission and preset priority requirements, and Dynamically adjust network parameters and path selection.

[0015] By adopting the above technical solution, in order to ensure the real-time and accuracy of data transmission between MECHATROLINK-Ⅲ master station, MECHATROLINK-Ⅲ coupler and plug-in IO module in industrial automation control system, the time deviation between them must be strictly controlled. However, in a complex network environment, due to factors such as network delay and equipment performance difference, time deviation is often difficult to avoid, which in turn affects the synchronization and stability of the system. In addition, the real-time and priority requirements of different data packets are different. Therefore, the data synchronization module accurately controls the time deviation, intelligently schedules the communication traffic, and dynamically adjusts the network parameters and path selection to ensure the real-time and accuracy of data transmission, while optimizing the utilization of network resources; the data synchronization module first adopts a high-precision time synchronization mechanism, such as IEEE 1588 (PTP) protocol, to ensure that the time deviation between MECHATROLINK-Ⅲ master station, coupler and plug-in IO module is within a predetermined range, and eliminates the time deviation caused by network delay and equipment performance difference through regular time synchronization operations. According to the real-time and preset priority requirements of data transmission, the data synchronization module intelligently schedules the communication traffic. By identifying the priority and real-time requirements of different data packets, it adopts appropriate scheduling algorithms (such as priority queues, time window scheduling, etc.) to ensure that critical data is transmitted first while reducing the waiting time of non-critical data. The data synchronization module also has the ability to dynamically adjust network parameters and path selection. When the network load is high or a failure occurs, the module will automatically adjust the network parameters (such as bandwidth allocation, transmission rate, etc.) and select the optimal transmission path to ensure the continuity and stability of data transmission. In addition, the module will continuously optimize and adjust the network configuration according to changes in network status to adapt to the ever-changing needs of industrial automation control.

[0016] In a preferred example, the present application can be further configured as follows: the data redundancy check module is used to perform cyclic redundancy check calculation on the transmitted data packet, generate a check code and attach it to the data packet, and Performing the same cyclic redundancy check calculation on the received data packet at the receiving end and comparing it with the check code in the data packet to verify the integrity and correctness of the data, and When data errors are found, corresponding processing is performed according to the preset error handling strategy.

[0017] By adopting the above technical solution, in order to ensure the integrity and correctness of the data packets transmitted between the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module in the industrial automation control system, and to prevent data damage or loss caused by errors or interference in the data transmission process, data verification is required. However, the traditional verification method may not be able to fully cover every byte in the data packet, or the verification process is complicated and inefficient, which is difficult to meet the requirements of the industrial automation control system for high reliability and real-time data transmission. Therefore, the data redundancy check module adopts the cyclic redundancy check (CRC) algorithm. At the sending end, the data redundancy check module first performs CRC calculation on the data packet. For example, the data packet is regarded as a binary sequence, and a specific CRC algorithm (such as CRC-32, CRC-16, etc.) is applied to perform polynomial division operation. After the calculation, a remainder of a fixed length is finally obtained as the check code, which is then attached to the data packet and sent together with the data packet. After the data redundancy check module at the receiving end receives the data packet, it first extracts the check code in the data packet. The module performs the same CRC calculation on the data packet (excluding the check code part) as the sending end. After the calculation is completed, the module compares the obtained CRC value with the check code in the data packet. If the two are consistent, it means that the data packet has not been damaged or tampered with during the transmission process. If they are inconsistent, it means that there is an error in the data packet to verify the integrity and correctness of the data. Once a data error is found, the module will perform corresponding processing according to the preset error handling strategy to ensure the reliability of data transmission, for example, requesting the retransmission of the erroneous data packet, recording the error log for subsequent analysis, or triggering a specific system recovery process according to the error type.

[0018] In a preferred example, the present application can be further configured as follows: the intelligent monitoring and feedback module is used to monitor the stability index and synchronization status of the data transmission process in real time, and Analyze the monitored data according to the preset abnormal threshold, detect abnormal situations in data transmission, and When an abnormal situation is detected, a corresponding processing flow is triggered according to a preset feedback processing mechanism corresponding to the abnormal threshold.

[0019] By adopting the above technical solutions, in the industrial automation control system, the data transmission between the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module is the key to the stable operation of the system. However, due to the complexity of the network environment, the difference in equipment performance and external interference and other factors, abnormal conditions such as stability degradation and synchronization loss may occur during the data transmission process. If they are not monitored and processed in time, the overall performance and reliability of the system will be seriously affected. Therefore, the intelligent monitoring and feedback module first monitors the stability of the data transmission process in real time by collecting key indicators such as network traffic, data packet delay and packet loss rate. At the same time, the module also uses the time synchronization mechanism to monitor the synchronization of data transmission. The module monitors the synchronization status to ensure that the time deviation between devices is within a controllable range. On the basis of real-time monitoring, the module analyzes the monitored data according to the preset abnormal thresholds, such as the maximum delay time, the maximum packet loss rate and the minimum synchronization accuracy. Once the monitored data exceeds these thresholds, the module will determine that the data transmission is abnormal. When an abnormality is detected, the intelligent monitoring and feedback module will trigger the corresponding processing flow according to the preset feedback processing mechanism corresponding to the abnormal threshold, such as adjusting network parameters, optimizing data transmission paths, requesting retransmission of lost data packets, and triggering system alarms. Through these processing flows, the module can quickly respond to abnormal situations and restore the stability and synchronization of data transmission. In the second aspect, the above invention objective of the present application is achieved through the following technical solutions: A communication method of a coupler system based on MECHATROLINK-Ⅲ, the communication method comprising: S1. The MECHATROLINK-Ⅲ coupler starts self-test and scans all slots of the MECHATROLINK-Ⅲ coupler to determine the slot with the plug-in IO module; S2, forming a configuration book according to the plug-in IO modules scanned in S1, wherein the configuration book is stored in the memory of the MECHATROLINK-III coupler in the form of a structure array; S3, the MECHATROLINK-III coupler starts initialization of the MECHATROLINK-III communication module, so that the MECHATROLINK-III coupler enters the MECHATROLINK-III slave station communication state; S4, the MECHATROLINK-Ⅲ coupler reads the input data X1-Xm of each plug-in IO module in the configuration book stored in the memory according to the slot number in ascending order; S5, storing the input data X1-Xm read in S4 in a preset SendBuff in order, and sending the input data X1-Xm to the MECHATROLINK-Ⅲ master station when a read instruction from the MECHATROLINK-Ⅲ master station arrives; S6, the MECHATROLINK-Ⅲ coupler obtains the output data Y1~Yn received from the MECHATROLINK-Ⅲ master station within the specified time according to the instruction received from the MECHATROLINK-Ⅲ master station; S7, the MECHATROLINK-III coupler outputs data Y1-Yn to each plug-in IO module in the configuration book according to the slot number in ascending order according to the configuration book stored in the memory; S8. The MECHATROLINK-Ⅲ coupler detects the error status of each plug-in IO module in the configuration book every 100 ms, and reports the status of each plug-in IO module in the configuration book to the MECHATROLINK-Ⅲ master station.

[0020] S9. Repeat steps S3 to S8.

[0021] By adopting the above technical solution, in the industrial automation control system, the MECHATROLINK-Ⅲ coupler, as a key device connecting the MECHATROLINK-Ⅲ master station and multiple plug-in IO modules, needs to efficiently manage the data communication between these modules. However, traditional communication methods may have problems such as low communication efficiency, poor data synchronization, and untimely error status monitoring, which affect the stability and reliability of the industrial automation control system. Based on this, the MECHATROLINK-Ⅲ coupler first performs a self-check when the system starts to ensure that its hardware and software status are normal. Then, it scans all slots to identify which slots have IO modules inserted, and prepares basic data for subsequent communication. According to the scanning results, the MECHATROLINK-Ⅲ coupler constructs a data structure stored in the form of a structure array, namely a configuration book, which is used to record the information and status of each plug-in IO module. After completing the configuration book construction, the MECHATROLINK-Ⅲ coupler starts its MEC The initialization process of the HATROLINK-Ⅲ communication module enables the coupler to communicate with the MECHATROLINK-Ⅲ master station as a slave station. The coupler reads the input data of each IO module in the order of the slot number and stores the data in SendBuff. When receiving the read instruction from the master station, the coupler sends the data in SendBuff to the master station. The coupler receives the output data from the master station and sends the data accurately to the corresponding IO module according to the information in the configuration book. In order to ensure the stable operation of the system, the coupler detects the error status of each IO module every 100ms and reports the status information to the master station. In this way, the master station can understand the health status of the system in time and take corresponding measures. In this way, the comprehensive control and management of the communication process of the MECHATROLINK-Ⅲ coupler system is realized, the stability and reliability of the system are improved, and at the same time, the efficiency and synchronization of data communication are improved to ensure the normal operation of the industrial automation control system.

[0022] In a preferred example, the present application may be further configured as follows: storing the input data X1-Xm read in S4 in sequence into a preset SendBuff, including: The input data X1-Xm are encoded using a preset compression algorithm to generate compressed data, and the compressed data are stored in a preset SendBuff in sequence.

[0023] By adopting the above technical solution, according to the characteristics of the input data and system requirements, a suitable compression algorithm is selected with a high compression ratio and a low decompression time to ensure the efficiency and real-time performance of data transmission. After reading the input data X1~Xm, the preset compression algorithm is used to encode these data. During the encoding process, the algorithm will analyze the redundant part of the data and compress it to generate compressed data with a smaller volume. The compressed data is stored in the preset SendBuff in sequence. Since the data has been compressed, SendBuff can store more data or occupy less memory space with the same amount of data. When the read instruction of the MECHATROLINK-Ⅲ master station arrives, the compressed data in SendBuff is sent to the master station. Since the data volume is reduced, the transmission time will be shortened accordingly, thereby improving the efficiency of data transmission. After the data arrives at the master station, the master station will use the same compression algorithm to decompress the data to restore the original data.

[0024] In a preferred example, the present application may be further configured as follows: after step S8, the communication method further includes: Monitoring the workload and communication requirements of the MECHATROLINK-III coupler and plug-in IO modules; According to the monitoring results, the rationality of the current communication cycle is analyzed. If the current communication cycle cannot meet the workload and communication requirements, a new communication cycle is calculated and determined.

[0025] By adopting the above technical solution, in the industrial automation control system, the MECHATROLINK-Ⅲ coupler and the plug-in IO modules connected thereto bear heavy data communication tasks. As the system scale expands and the complexity increases, the workload and communication requirements of these devices may also change dynamically. If the communication cycle is fixed, it may not be able to adapt to such changes, resulting in communication delays, data loss or system performance degradation. Therefore, the workload and communication requirements of the MECHATROLINK-Ⅲ coupler and the plug-in IO module are monitored, including key indicators such as CPU usage, memory usage, data transmission volume and data packet delay. According to the monitored data, the system analyzes the rationality of the current communication cycle, and evaluates whether there is a communication bottleneck or resource waste by comparing the matching degree between the actual communication demand and the current communication cycle. If the analysis results show that the current communication cycle cannot meet the workload and communication requirements, a new communication cycle will be automatically calculated and determined. This new cycle will be based on comprehensive consideration of factors such as monitoring data, system performance requirements and user-set priorities. After determining the new communication cycle, adjustments will be implemented before the start of the next communication cycle, including updating relevant configuration parameters, notifying all relevant devices and ensuring that all devices can work normally under the new cycle.

[0026] In summary, the present application includes at least one of the following beneficial technical effects: 1. In modern industrial automation control systems, with the increase in the number and complexity of equipment, traditional IO (input and output) management methods face problems such as insufficient scalability, low communication efficiency, and high system maintenance costs. In particular, when using the MECHATROLINK-Ⅲ protocol for large-scale equipment interconnection, it is difficult to efficiently manage many plug-in IO modules and ensure orderly data transmission and real-time synchronization. Therefore, the complex multiple MECHATROLINK-Ⅲ dedicated cables are simplified into one MECHATROLINK-Ⅲ dedicated cable to facilitate the troubleshooting of communication line faults, and multiple IO-type devices are changed to plug-in IO modules to reduce the operation failures of automated production lines caused by cable connection errors. By integrating the control unit and the execution unit in the MECHATROLINK-Ⅲ coupler, efficient management and orderly control of all plug-in IO modules in the slot are achieved, and the connection with the MECHATROLINK-Ⅲ master station is optimized. The communication interaction mechanism has greatly improved the overall performance and reliability of the system. A system architecture is constructed with the MECHATROLINK-Ⅲ master station as the core, which is connected to the MECHATROLINK-Ⅲ coupler through a dedicated cable. Multiple control units are integrated inside the coupler to manage and schedule the plug-in IO modules in each slot. The MECHATROLINK-Ⅲ coupler uses its internal control unit to monitor and dynamically configure each plug-in IO module in the slot in real time to ensure that each module can perform IO operations in a predetermined order and rules. It also uses efficient communication protocols and scheduling algorithms to optimize the data transmission process between the MECHATROLINK-Ⅲ coupler and the master station. Through intelligent data compression and decompression technology, the data transmission volume is reduced and the communication efficiency is improved. In addition, according to the real-time load of the system, the communication bandwidth allocated to each plug-in IO module is dynamically adjusted to ensure that key data can be transmitted first while avoiding network congestion. 2. In industrial automation control systems, MECHATROLINK-Ⅲ couplers are key devices that connect the MECHATROLINK-Ⅲ master station with multiple plug-in IO modules. They need to efficiently manage data communications between these modules. However, traditional communication methods may have problems such as low communication efficiency, poor data synchronization, and untimely error status monitoring, which affect the stability and reliability of industrial automation control systems. Based on this, the MECHATROLINK-Ⅲ coupler first performs a self-check when the system starts to ensure that its hardware and software are in normal condition. Subsequently, it scans all slots to identify which slots have IO modules inserted, and prepares basic data for subsequent communications. Based on the scan results, the MECHATROLINK-Ⅲ coupler constructs a data structure stored in the form of a structure array, namely a configuration book, which is used to record the information and status of each plug-in IO module. After completing the configuration book construction, the MECHATROLINK-Ⅲ coupler starts its MECHATROLINK-Ⅲ coupler. The initialization process of the OLINK-Ⅲ communication module enables the coupler to communicate with the MECHATROLINK-Ⅲ master station as a slave station. The coupler reads the input data of each IO module in the order of the slot number and stores the data in SendBuff. When receiving the read instruction from the master station, the coupler sends the data in SendBuff to the master station. The coupler receives the output data from the master station and sends the data accurately to the corresponding IO module according to the information in the configuration book. In order to ensure the stable operation of the system, the coupler detects the error status of each IO module every 100ms and reports the status information to the master station. In this way, the master station can understand the health status of the system in time and take corresponding measures. In this way, the comprehensive control and management of the communication process of the MECHATROLINK-Ⅲ coupler system is realized, the stability and reliability of the system are improved, and at the same time, the efficiency and synchronization of data communication are improved to ensure the normal operation of the industrial automation control system. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the principle structure of the coupler system based on MECHATROLINK-Ⅲ in the embodiment of the present application.

[0028] Figure 2 It is the first implementation flow chart of the communication method of the coupler system based on MECHATROLINK-Ⅲ in the embodiment of the present application.

[0029] Figure 3 This is a second implementation flow chart of the communication method of the coupler system based on MECHATROLINK-Ⅲ in the embodiment of the present application. DETAILED DESCRIPTION

[0030] The following is combined with Figure 1-3This application is described in further detail.

[0031] In one embodiment, if Figure 1 As shown, the present application discloses a coupler system based on MECHATROLINK-Ⅲ, the coupler system includes a MECHATROLINK-Ⅲ master station, a MECHATROLINK-Ⅲ dedicated cable, a MECHATROLINK-Ⅲ coupler and a plurality of plug-in IO modules, the MECHATROLINK-Ⅲ coupler is used to manage all the plug-in IO modules in the slot for orderly IO input and output, and is responsible for the communication interaction between the IO data of the entire coupler system and the MECHATROLINK-Ⅲ master station.

[0032] In order to manage multiple plug-in IO modules in the slots, the MECHATROLINK-Ⅲ coupler adopts a modular slot design, and each slot is equipped with a standardized electrical interface and mechanical structure. The MECHATROLINK-Ⅲ coupler integrates an intelligent slot manager, which monitors the status of each slot in real time through the control of a microprocessor, including the existence, type and configuration information of the module, and performs orderly data transmission and IO operations accordingly.

[0033] In terms of communication, the MECHATROLINK-Ⅲ coupler integrates a dedicated communication interface module, follows the MECHATROLINK-Ⅲ standard protocol, and realizes serial communication with the master station. In addition, the MECHATROLINK-Ⅲ coupler also supports multiple communication modes, such as polling and interruption, to adapt to different application scenarios and needs.

[0034] In order to improve the control capability and execution efficiency of the system, the MECHATROLINK-Ⅲ coupler also integrates multiple control units and execution units. The control unit has a built-in programmable logic controller (PLC) function, and users can implement complex control logic and algorithms through programming. These control logics can be automatically adjusted according to external signals or preset conditions to meet the needs of different processes and equipment; the execution unit is responsible for converting control instructions into actual physical actions, and is connected to external devices (such as motors, cylinders, etc.) through high-precision drive circuits to achieve precise position control, speed regulation, force feedback and other functions.

[0035] At the software level, MECHATROLINK-Ⅲ coupler uses real-time operating system (RTOS) as the software platform. RTOS provides functions such as multi-task scheduling, time management and interrupt processing, ensuring the high real-time and high reliability of the system. With the support of RTOS, it can handle multiple tasks at the same time and schedule them according to the priority of the tasks to ensure that key tasks can be executed in time.

[0036] In addition, the MECHATROLINK-Ⅲ protocol stipulates that an axis can only have 60 bytes of input and 60 bytes of output. However, when all plug-in IO modules are fully inserted, 300 bytes of input and 300 bytes of output are required. Therefore, the MECHATROLINK-Ⅲ coupler is designed to integrate 5 axes to meet the application requirements.

[0037] In one embodiment, the coupler system further comprises: The data synchronization module is used to achieve time synchronization and traffic scheduling. In this embodiment, the data synchronization module adopts the IEEE 802.1AS time synchronization protocol. Through a high-precision clock source and a synchronization message exchange mechanism, it ensures that the time error of all devices in the network is within the microsecond or even nanosecond range. For example, a high-precision clock source, such as an atomic clock or a GPS synchronized clock, is used as a time reference to provide a stable and reliable time reference for the entire network. In addition, the data synchronization module is integrated with a clock compensation algorithm to cope with network delays and jitters, and further reduce the time error to the nanosecond level. In addition, the data synchronization module is also integrated with a traffic shaping and scheduling algorithm, which can intelligently allocate network resources according to the priority and real-time requirements of the data, avoid network congestion, and ensure low-latency transmission of key control data, such as credit-based flow control and gate control list technology. The MECHATROLINK-Ⅲ coupler contains a dedicated chip that communicates with the MECHATROLINK-Ⅲ master station. The chip generates an external interrupt to the interrupt receiving end of the microcontroller every millisecond. If multiple MECHATROLINK-Ⅲ slave stations are used, multiple MECHATROLINK-Ⅲ communication chips will generate multiple asynchronous one-millisecond interrupts. Since the clock of each MECHATROLINK-Ⅲ core dedicated communication chip is not synchronized, it will cause the communication of each IO module to be asynchronous. Therefore, a dedicated communication chip is used to trigger a one-millisecond timing interrupt. This will solve the communication asynchronous problem caused by multiple MECHATROLINK-Ⅲ communication chips, because the synchronization problem is triggered by the same one-millisecond terminal, thus solving the synchronization problem; The data redundancy check module is used to perform cyclic redundancy check on data packets. It uses the cyclic redundancy check (CRC) algorithm to calculate the check code for each data packet sent, and attach the check code to the end of the data packet and send it together. After receiving the data packet, the receiving end will recalculate the check code and compare it with the check code attached to the sending end to verify the integrity of the data. Once a data error is found, the system can immediately trigger the retransmission mechanism to ensure the accurate transmission of the data; Furthermore, polynomial checksum and hash check can also be used. In practical applications, the data redundancy check module will flexibly select a suitable check algorithm according to the characteristics of the data packet and the transmission requirements. At the same time, in order to improve the check efficiency, the data redundancy check module also adopts parallel processing and pipeline technology. Once a data error is found, the data redundancy check module will immediately start the retransmission mechanism and record the error log for subsequent analysis. In addition, the data redundancy check module also supports an adaptive retransmission strategy, which dynamically adjusts the number and interval of retransmissions according to the network status and error type to ensure the final accurate transmission of the data.

[0038] The dynamic bandwidth allocation module is used to monitor the traffic in the network in real time according to the operation requirements, including the data transmission volume and priority requirements of each node, and automatically identify and classify different types of data streams, and dynamically adjust the bandwidth allocation of the MECHATROLINK-Ⅲ coupler. Specifically, it can use multi-queue scheduling algorithms (such as FQ-CoDel, PIE, etc.) to allocate independent queues and bandwidth resources to each priority data stream, and through the bandwidth borrowing and sharing mechanism, it can reasonably use idle bandwidth resources and improve the overall network utilization while ensuring the priority transmission of high-priority data; The predictive data synchronization module is used to predict data synchronization needs by analyzing historical data and current status, and to build a data synchronization demand prediction model. Through the data synchronization demand prediction model, the predictive data synchronization module can predict data synchronization needs in advance, and pre-allocate resources and optimize the network accordingly. In order to achieve more efficient prediction and scheduling, the predictive data synchronization module also includes edge computing and cloud collaboration mechanisms. The edge computing nodes are responsible for collecting and processing local data and quickly responding to real-time needs, while the cloud is responsible for storing and analyzing global data, providing long-term trend prediction and global optimization strategies. In actual applications, the predictive data synchronization module will schedule network resources in advance according to the prediction results, optimize the data transmission path, and reserve sufficient bandwidth and cache resources to cope with sudden demands. The intelligent monitoring and feedback module is used to monitor the stability and synchronization of data transmission in real time. The intelligent monitoring and feedback module integrates a variety of sensors and monitoring tools to comprehensively monitor the stability, synchronization and operating status of data transmission and network equipment. At the same time, once an abnormality or fault is detected, the intelligent monitoring and feedback module will immediately trigger the corresponding processing flow, including but not limited to retransmission mechanism, error correction, equipment restart and fault isolation, etc., to quickly restore the normal operation of the system and reduce losses; in addition, the intelligent monitoring and feedback module will also feed back the monitored data and analysis results to the system management or maintenance personnel to provide decision support and optimization suggestions.

[0039] In one embodiment, the dynamic bandwidth allocation module is integrated into the MECHATROLINK-Ⅲ master station and connected to each plug-in IO module (such as a servo drive, a sensor interface, etc.) through a bus. The dynamic bandwidth allocation module includes a data acquisition unit, a communication load analysis unit, a priority determination unit, a bandwidth allocation execution unit, and a feedback and adjustment unit. The dynamic bandwidth allocation module is used to monitor the communication load between the MECHATROLINK-Ⅲ master station and each plug-in IO module in real time, and judge the importance and urgency of the communication data according to the communication load, analyze and determine the priority of the data, and Dynamically adjust the communication bandwidth allocated to each plug-in IO module based on the communication load and data priority; Specifically, The data acquisition unit collects the communication data packets between the master station and each plug-in IO module in real time by setting the data acquisition points and configuring the data acquisition frequency, including the data packet size, sending time and receiving confirmation information; The communication load analysis unit conducts statistical analysis on the collected communication data by establishing a communication load model and traffic statistics, calculates the current network status according to the model parameters, and calculates key indicators such as the communication load rate of each node, the average delay of data packets, and the packet loss rate; The priority determination unit is provided with a priority determination standard specified based on a preset analysis of a business scenario, and a matching priority determination algorithm, and the priority determination standard and the priority determination algorithm are associated as a priority determination rule for communication data, so that the algorithm is applied to the collected communication data to assign a priority label to each data packet; the analysis of the business scenario can be based on factors such as data type (such as control commands, status feedback, monitoring data, etc.), data size and real-time requirements; The bandwidth allocation execution unit can implement dynamic bandwidth allocation algorithms, such as proportional allocation method, priority queue method, etc. For example, the priority queue method dynamically adjusts the bandwidth allocation of each node based on the communication load and data priority. Specifically, firstly, the data packets are classified into different priority queues according to the priority determination result, and the bandwidth quota of each priority queue is calculated according to the current network status and bandwidth resource situation. Finally, the dynamic allocation of bandwidth is realized by adjusting the network configuration or sending a control signal. The feedback and adjustment unit is provided with a closed-loop control mechanism, that is, by monitoring the changes in network performance after bandwidth allocation (such as delay and packet loss rate, etc.), evaluating the bandwidth allocation effect, and adjusting the bandwidth allocation strategy according to the evaluation results. For example, by setting performance monitoring points, collecting network performance data regularly or in a triggered manner, and comparing and analyzing the monitoring data with the preset performance indicators, it is determined whether the bandwidth allocation meets the demand. If not, the bandwidth allocation strategy is adjusted according to the analysis results, and the bandwidth allocation process is re-executed.

[0040] In one embodiment, the predictive data synchronization module can be integrated into the monitoring layer of the MECHATROLINK-Ⅲ system, and is closely connected with the master station, the coupler, and each plug-in IO module. The predictive data synchronization module includes a data acquisition unit, an anomaly recognition unit, a machine learning analysis unit, a fault prediction unit, and a fast recovery strategy execution unit; The predictive data synchronization module is used to monitor the operating status data of the MECHATROLINK-Ⅲ master station, couplers and plug-in IO modules in real time, identify abnormal data, and Use machine learning algorithms to analyze abnormal data, predict failure type and time, and Trigger predefined fast recovery strategies based on fault type and time; Specifically, The data acquisition unit captures the operating status data of the MECHATROLINK-Ⅲ master station, coupler and plug-in IO modules in real time by setting the data acquisition frequency and accuracy requirements and configuring data acquisition points covering all key components and communication links, including but not limited to temperature, voltage, current, communication status, etc.; The abnormality identification unit compares the real-time data with the benchmark model by establishing a benchmark model of normal operating conditions and setting an abnormality threshold. Data exceeding the threshold is considered abnormal data and marked and recorded. In addition, the collected operating status data can be analyzed in real time through statistical analysis and pattern recognition to identify abnormal data that deviates from the normal mode. The machine learning analysis unit uses the trained model to perform predictive analysis on new abnormal data and output the fault type and expected occurrence time. In the machine learning analysis unit, the training data set of the model includes historical fault data and corresponding operating status data. It conducts in-depth analysis on the abnormal data and mines the rules and features behind the data to predict the possible fault type and time. The model type can be random forest, neural network, etc. The fault prediction unit is set with fault prediction thresholds and priority sorting rules. The fault prediction unit first evaluates the possibility and urgency of the fault based on the output results of the machine learning analysis unit, combined with the current operating status of the system and external environmental factors (such as temperature, humidity, etc.), and then generates fault warning information based on the prediction results and sorting rules, including fault type, expected time of occurrence and scope of impact, etc.; The quick recovery strategy execution unit will automatically trigger the predefined quick recovery strategy according to the warning information generated by the fault prediction unit, including fault isolation, resource reallocation and backup equipment startup. In the quick recovery strategy execution unit, quick recovery strategies for different fault types are formulated and encoded as executable programs or scripts. When the fault warning information is received, the corresponding recovery strategy execution program is immediately started, and the fault is handled according to the preset steps. At the same time, the recovery process and results are recorded to provide data support for subsequent optimization and improvement.

[0041] In one embodiment, the data synchronization module is integrated into the network management layer of the MECHATROLINK-III system, connected to the master station, the coupler and the plug-in IO module, and the data synchronization module includes a time synchronization unit, a traffic scheduling unit, a network parameter adjustment unit and a path selection optimization unit; The data synchronization module is used to control the time deviation between the MECHATROLINK-Ⅲ master station, MECHATROLINK-Ⅲ coupler and plug-in IO modules within a predetermined range, and Scheduling communication traffic according to the real-time nature of data transmission and preset priority requirements, and Dynamically adjust network parameters and path selection; Specifically, The time synchronization unit configures a time synchronization server (usually a master station), sets the time synchronization cycle and accuracy requirements, adopts a high-precision time synchronization protocol (such as IEEE 802.1AS), uses the master station as the time reference, integrates the time synchronization client in the coupler and plug-in IO module, receives and applies time information, and realizes system-level time synchronization; The traffic scheduling unit finely schedules the communication traffic based on mechanisms such as credit-based traffic shaping (CBS) and time-aware shaping (TAS) according to the real-time nature of data transmission and preset priority requirements. Specifically, the traffic scheduling unit has priority rules for defining data transmission, including real-time control commands, periodic status updates, and non-real-time data, and configures the traffic scheduler to allocate credit values ​​and time slots for different data streams according to priority and real-time requirements, and then monitors network traffic to dynamically adjust credit values ​​and time slot allocations to ensure low-latency transmission of critical data; The network parameter adjustment unit is equipped with a network performance monitoring point to collect performance data regularly or in a triggered manner, monitor network performance parameters (such as delay, jitter, packet loss rate, etc.) in real time, analyze performance data based on monitoring results, identify network bottlenecks and potential problems, and dynamically adjust network parameters (such as bandwidth allocation, buffer size, and retransmission mechanism, etc.) based on the analysis results to optimize network performance; The path selection optimization unit can select the optimal path for data transmission through a path calculation algorithm (such as the shortest path algorithm or the multi-path algorithm), combined with the network topology and real-time performance data. For example, it can build a network topology map, collect the performance parameters of each link (such as delay, bandwidth, reliability, etc.), and use the path calculation algorithm to calculate the optimal path according to the requirements of data transmission (such as real-time, reliability, etc.). During the data transmission process, the path performance is monitored in real time. If performance degradation or failure is found, it will quickly switch to the backup path.

[0042] In one embodiment, the data redundancy check module is embedded in the communication protocol stack of the sending end and the receiving end as a part of the data transmission link, and includes a data redundancy check calculation unit, a check code addition unit, a receiving check unit and an error processing unit; The data redundancy check module is used to perform cyclic redundancy check calculation on the transmitted data packet, generate a check code and attach it to the data packet, and The receiving end performs the same cyclic redundancy check calculation on the received data packet and compares it with the checksum in the data packet to verify the integrity and correctness of the data, and When data errors are found, corresponding processing is performed according to the preset error handling strategy; Specifically, The data redundancy check calculation unit uses a standard CRC algorithm (such as CRC-8, CRC-16, CRC-32, etc.) to take the data packet to be sent as input, performs polynomial division operation according to the content of the data packet, and generates a check code of fixed length; further, according to the characteristics and requirements of data transmission, a suitable CRC algorithm and polynomial can be dynamically selected to balance the strength of the check and the consumption of computing resources. In addition, on the basis of data redundancy check, combined with error correction code (such as Hamming code, RS code, etc.), the detected errors are corrected to further improve the reliability of data transmission; The check code appending unit appends the check code to the end of the data packet, and the data packet containing the check code is then sent to the network; After receiving the data packet, the receiving verification unit separates the original data and the attached verification code from the received data packet, and also uses the same CRC algorithm to calculate the data packet (excluding the original verification code) to generate a new verification code, and then compares the newly generated verification code with the verification code attached to the data packet; The error handling unit defines a variety of error handling strategies, including retransmission request, error log recording, data recovery attempt (such as using error correction code) or directly discarding the error data packet. When a data error is found, the appropriate handling strategy is selected according to the nature and importance of the error and the current state of the system. For example, for errors in critical control commands, a retransmission request may be triggered; for errors in non-critical data, a log may be recorded and subsequent data processing may continue; In one embodiment, the intelligent monitoring and feedback module is integrated into the system monitoring layer and connected to the data transmission link, and includes a data acquisition unit, a data analysis unit, an anomaly detection unit, and a feedback processing unit; The intelligent monitoring and feedback module is used to monitor the stability indicators and synchronization status of data transmission in real time, and Analyze the monitored data according to the preset abnormal threshold, detect abnormal situations in data transmission, and When an abnormal situation is detected, the corresponding processing flow is triggered according to the preset feedback processing mechanism corresponding to the abnormal threshold; Specifically, The data collection unit uses hardware devices such as sensors or network probes, as well as software-level log analysis and performance monitoring tools, to configure data collection points, and collect stability indicators (packet loss rate, delay and jitter) and synchronization status (time deviation and synchronization accuracy) during data transmission on a regular or real-time basis to ensure that key paths and nodes of data transmission are covered, and stored in the database for subsequent analysis; The data analysis unit will first set abnormal thresholds for various stability indicators and synchronization status according to system characteristics and business requirements, and compare the real-time data with the preset thresholds to detect whether there are any situations that exceed the thresholds; The anomaly detection unit defines a variety of anomaly handling strategies, such as automatic retransmission, alarm notification, system degradation, and fault isolation; When the feedback processing unit detects an abnormal situation, it selects an appropriate processing strategy based on the specific situation of the abnormality (type and severity of the abnormality) and the preset feedback processing mechanism. For example, for slight delays or jitters, only logging may be performed; for severe packet loss or time deviation, automatic retransmission or alarm notification may be triggered.

[0043] Each module in the above-mentioned MECHATROLINK-Ⅲ based coupler system can be implemented in whole or in part by software, hardware and their combination. Each of the above-mentioned modules can be embedded in or independent of the processor in the computer device in the form of hardware, or can be stored in the memory in the computer device in the form of software, so that the processor can call and execute the corresponding operations of each of the above modules.

[0044] In one embodiment, if Figure 2As shown, the present application discloses a communication method of a coupler system based on MECHATROLINK-Ⅲ, which specifically includes the following steps: S1. The MECHATROLINK-Ⅲ coupler starts self-test and scans all slots of the MECHATROLINK-Ⅲ coupler to determine the slots with plug-in IO modules.

[0045] Specifically, in the startup sequence of the MECHATROLINK-Ⅲ communication system, the first step is crucial, that is, the MECHATROLINK-Ⅲ coupler performs a comprehensive self-test process, starting with power supply detection to ensure a stable power supply, followed by checking the functional status of key components such as internal circuits, communication interfaces, and microprocessors, and verifying integrity and performance by running a series of diagnostic tests. After the self-test passes, it enters the slot scanning phase. In the scanning phase, the coupler uses a built-in scanning mechanism to check all its available physical slots one by one in a preset order. Each slot is designed with a specific electrical interface and identification mechanism for communicating with plug-in IO modules. When a slot is scanned, the coupler sends a specific signal or executes an identification protocol to detect whether there is an IO module in the slot; If a module is detected in the slot, the coupler will further verify the compatibility and type of the module, for example, by reading the information in the EEPROM (Electrically Erasable Programmable Read-Only Memory) or other storage elements on the module, including key data such as the manufacturer, model, version, and supported communication protocols of the module. By comparing this information, the coupler can confirm whether the module is suitable for the current MECHATROLINK-Ⅲ system and allocate corresponding resources to it. After comprehensive scanning and verification, the MECHATROLINK-Ⅲ coupler will generate a slot status report, listing all inserted and compatible IO modules and their corresponding slot numbers, providing the necessary reference and basis for subsequent system configuration, configuration book construction and data communication.

[0046] S2. According to the plug-in IO modules scanned in S1, a configuration book is formed, and the configuration book is stored in the memory of the MECHATROLINK-Ⅲ coupler in the form of a structure array.

[0047] In this embodiment, the configuration book is the core data structure used to manage and maintain the configuration information of all plug-in IO modules in the MECHATROLINK-Ⅲ system.

[0048] Specifically, first, the coupler will extract the information of all inserted and compatible IO modules according to the slot status report generated in step S1, including the identifier of the single module (such as serial number or model code), type (such as digital input / output, analog input / output, etc.), address (unique location identifier in the MECHATROLINK-Ⅲ network), number and configuration of input and output channels (such as whether the channel is activated, input and output mode, etc.), then, the coupler will allocate a continuous area in the memory to store the configuration book. In this embodiment, in order to efficiently manage and access these data, the coupler organizes the configuration book in the form of a structure array, each structure corresponds to an IO module, and contains all relevant configuration information of the module; In the process of building the configuration book, the coupler will traverse all identified IO modules and create a corresponding structure instance for each module. The instances will be added to the structure array in sequence and sorted in a logical order such as slot number or module type. The purpose of sorting is to optimize the subsequent data processing and communication process, so that the system can locate a specific module more quickly and perform corresponding operations; When the configuration information of all IO modules has been correctly filled into the configuration book, the coupler will conduct a comprehensive verification of it, including checking the integrity and consistency of the data and whether it complies with the requirements of the MECHATROLINK-Ⅲ communication protocol.

[0049] S3. The MECHATROLINK-Ⅲ coupler starts the initialization of the MECHATROLINK-Ⅲ communication module, so that the MECHATROLINK-Ⅲ coupler enters the MECHATROLINK-Ⅲ slave station communication state.

[0050] Specifically, the coupler activates its built-in MECHATROLINK-Ⅲ communication module, which is responsible for handling all communication tasks related to the MECHATROLINK-Ⅲ network, including the sending, receiving, parsing and error handling of data packets. During the activation process, the coupler configures the communication module parameters, such as baud rate, data bits, stop bits and parity bits, to ensure that it is consistent with the communication parameters of other devices in the network; Next, the coupler will perform a series of initialization operations to prepare for slave communication, including: Clear the communication buffer: Make sure there is no old data remaining in the internal buffer of the communication module to avoid data interference or conflict; Set slave address: assign a unique slave address to the coupler according to network configuration or user settings; Loading configuration book information: Load the previously constructed configuration book information into the corresponding area of ​​the communication module so that the configuration information of the IO module can be quickly accessed and updated during the communication process; Send slave ready signal: Send a signal to the master station in the network indicating that the coupler is ready. This signal is the trigger condition for the master station to start communicating with the coupler. After completing the above initialization operations, the MECHATROLINK-Ⅲ coupler officially enters the slave communication state. In this state, the coupler will continuously monitor the communication requests and data packets on the network. When receiving the data packet sent by the master station, the coupler will parse and process it according to the requirements of the MECHATROLINK-Ⅲ communication protocol, and send a response data packet to the master station or update the status information of the IO module as needed.

[0051] S4. MECHATROLINK-Ⅲ coupler reads the input data X1~Xm of each plug-in IO module in the configuration book stored in the memory in the order of slot numbers from small to large.

[0052] Specifically, the coupler traverses the structure array in the configuration book and accesses it in order of slot numbers from small to large. For each structure instance in the configuration book, that is, each plug-in IO module, the coupler reads its input data. For example, the coupler first identifies the type of the current module based on the information in the structure, such as a digital input module and an analog input module. Different types of modules may have different data formats and ranges. After determining the module type, the coupler sends a specific communication instruction or data packet to request the module to send its current input data, so as to establish a communication connection with the corresponding IO module. After the communication connection is successfully established, the coupler reads the input data from the IO module, including the switch state (for digital input modules) and the voltage or current value (for analog input modules), etc., and then checks whether the data integrity and range meet expectations, and whether unit conversion or scaling is required. The input data after verification and conversion, such as X1~Xm (where X represents input data, 1~m represents different IO modules or channel numbers), will be stored in the coupler's memory; After reading and processing the input data of all IO modules, the coupler will update the corresponding status information in the configuration book to reflect the current input status.

[0053] S5. Store the input data X1~Xm read in S4 into the preset SendBuff in order, and when the read instruction of the MECHATROLINK-Ⅲ master station arrives, send the input data X1~Xm to the MECHATROLINK-Ⅲ master station.

[0054] In this embodiment, a buffer named SendBuff is preset in the internal memory of the coupler. The size and structure of this buffer are designed according to the system requirements and the requirements of the MECHATROLINK-Ⅲ communication protocol to ensure that it can accommodate all input data that need to be sent and reserve sufficient space for possible protocol overhead.

[0055] Specifically, the coupler stores the input data X1~Xm read in step S4 into SendBuff in the order defined in the configuration book. After the data is stored, SendBuff is in standby state, waiting for the read instruction from the MECHATROLINK-Ⅲ master station to arrive. The master station usually sends a read instruction to the coupler when it needs to update the system status or perform real-time control, requesting it to send the latest input data. When the master station's read instruction arrives, the coupler will respond immediately. According to the requirements in the instruction (such as data range and format, etc.), it will retrieve the corresponding input data X1~Xm from SendBuff and encapsulate and package it according to the requirements of the MECHATROLINK-Ⅲ communication protocol. The coupler will then send the encapsulated data packet to the network for the master station to receive and process.

[0056] During the transmission process, the coupler is also responsible for handling possible communication errors and abnormal situations. For example, if a timeout or checksum error occurs during the transmission process, the coupler will try to resend the data packet or report the error status to the master station.

[0057] S6. The MECHATROLINK-Ⅲ coupler obtains the output data Y1~Yn received from the MECHATROLINK-Ⅲ master station within the specified time according to the instructions received from the MECHATROLINK-Ⅲ master station.

[0058] Specifically, when the MECHATROLINK-Ⅲ master station needs to send control instructions or output data to the system, it will send a data packet containing specific instructions and data requests to the coupler through the communication network, including multiple output data items Y1~Yn, each of which corresponds to the output channel of a certain IO module in the system; After receiving the data packet sent by the master station, the coupler will immediately parse and process it, for example, verify the integrity and correctness of the data packet, including checking the checksum, and confirming the source and type of the data packet. If the data packet verification passes, the coupler will continue to parse the specific content in the data packet, and then receive the output data Y1~Yn from the master station within the specified time according to the instructions and data requests in the parsed data packet. After receiving all the output data, the coupler will temporarily store this data in one or more internal buffers for subsequent distribution and processing, and then distribute the received output data Y1~Yn to the corresponding IO modules according to the system configuration and the information in the configuration book.

[0059] S7, MECHATROLINK-Ⅲ coupler outputs data Y1~Yn to each plug-in IO module in the configuration book according to the slot number from small to large according to the configuration book stored in the memory.

[0060] Specifically, the coupler accesses the configuration book in the memory, which records the detailed information of all plug-in IO modules in the system, including slot number, type, address and data format, etc. This information determines how to correctly map the output data Y1~Yn to the output channel of each IO module. Therefore, the coupler will traverse all plug-in IO modules in the order of slot number from small to large according to the information in the configuration book. For each traversed IO module, the coupler will search for the corresponding output data item. Since the output data Y1~Yn has been sorted or grouped when received, the coupler needs to use the mapping relationship in the configuration book to match these data items with the output channel of the IO module. After finding the matching output data items, the coupler will send these data to the corresponding IO module through its built-in communication interface and protocol. During the data transmission process, the coupler will also monitor the communication status to ensure that each IO module can receive and process data normally. If a communication failure or data error occurs in an IO module, the coupler will record the corresponding error information and may report this status to the master station for subsequent troubleshooting and processing.

[0061] S8. The MECHATROLINK-Ⅲ coupler detects the error status of each plug-in IO module in the configuration book every 100ms, and reports the status of each plug-in IO module in the configuration book to the MECHATROLINK-Ⅲ master station.

[0062] Specifically, in the automation control system, monitoring and diagnosing the status of the IO module is a key link to ensure the stable operation of the system. Therefore, after the S7 step, the coupler will start a status detection cycle every 100ms. The selection of the time of the status detection cycle is based on the system's requirements for real-time performance and communication load considerations, in order to balance the timeliness of data updates and the effective use of system resources; At the beginning of the detection cycle, the coupler will first access the configuration book in the memory to obtain the list and related information of all plug-in IO modules, and traverse these IO modules in a predetermined order (slot number, module type or other logic); For each traversed IO module, the coupler will send a status query request through its built-in communication interface and protocol. This request will require the IO module to return its current operating status, error code (if any), and other possible status information; After receiving the status query request, the IO module will perform the corresponding status check operation and return the result to the coupler, including whether the module is online, whether there is a hardware fault, whether there is a communication error, and any specific status identification. After receiving the status information returned by the IO module, the coupler will store this information in one or more internal status registers; after completing the status detection of all IO modules, the coupler will organize the collected status information and package this information into a status report data packet in accordance with the specifications of the MECHATROLINK-Ⅲ protocol. The coupler will then send the status report data packet to the MECHATROLINK-Ⅲ master station through the communication network. After receiving this data packet, the master station will parse and process it to understand the current status of the entire automation control system.

[0063] S9. Repeat steps S3 to S8.

[0064] In this embodiment, whenever a complete cycle from S3 to S8 is completed, the MECHATROLINK-III coupler does not stop working, but immediately enters the next cycle and starts again from step S3; In step S3, the coupler checks again whether new input data (such as sensor readings, button status, etc.) has arrived from the MECHATROLINK-Ⅲ network or other input sources. If there is new input data, the coupler stores it in memory and prepares it for processing in subsequent steps.

[0065] Step S4 will pre-process the input data, including data verification, format conversion, and filtering, to ensure the accuracy and reliability of the input data; In step S5, the coupler will calculate or make decisions on the processed input data according to the predefined logic or algorithm to generate corresponding output data; In step S6, the coupler maps the output data to the output channel of the corresponding plug-in IO module according to the configuration information in the configuration book; Step S7 will execute the distribution of output data and send the generated output data to the corresponding IO modules through the MECHATROLINK-Ⅲ network; In step S8, the coupler will again detect the error status of each plug-in IO module in the configuration book and report the detected status information to the MECHATROLINK-Ⅲ master station; By continuously repeating steps S3 to S8, the MECHATROLINK-Ⅲ coupler can continuously monitor and control the automation control system, improve the system's response speed and accuracy, and enhance the system's stability and reliability.

[0066] In one embodiment, the input data X1-Xm read in S4 are stored in a preset SendBuff in sequence, including: The input data X1~Xm are encoded using a preset compression algorithm to generate compressed data, and the compressed data are stored in the preset SendBuff in sequence.

[0067] Specifically, a preset compression algorithm is used to encode the verified input data. The compression algorithm is selected based on system requirements and data characteristics, and can minimize the data volume while maintaining the recoverability and integrity of the data. Usually, it can be lossless compression, but lossy compression may also be used in specific cases. During the compression process, the coupler processes the input data X1 to Xm one by one, and for each data item, applies the corresponding function or algorithm logic in the compression algorithm to compress it, and then writes it into the preset SendBuff.

[0068] It should be noted that before storing the compressed data in SendBuff, the coupler may also need to perform some additional operations, such as adding a data header (containing information such as data length and type) and a checksum (used to verify data integrity).

[0069] In one embodiment, if Figure 3 As shown, after step S8, the communication method further includes: S81. Monitor the workload and communication requirements of MECHATROLINK-Ⅲ couplers and plug-in IO modules.

[0070] Specifically, it collects and analyzes the working status information from each IO module, including key indicators such as data processing volume, data transmission rate and response time, and then evaluates the current network status, such as bandwidth utilization and delay time, to fully understand the communication environment of the system.

[0071] Furthermore, by integrating this information, the coupler can build a dynamic workload and communication demand model, which not only reflects the current system operation status, but also predicts possible changing trends in the future.

[0072] S82. Analyze the rationality of the current communication cycle according to the monitoring results. If the current communication cycle cannot meet the workload and communication requirements, calculate and determine a new communication cycle.

[0073] Specifically, according to the monitoring results, if the coupler finds that the current communication cycle cannot meet the workload and communication requirements (for example, due to a surge in data volume, buffer overflow or extended response time, etc.), the communication cycle adjustment mechanism is started. For example, the specific cause of the communication bottleneck is first analyzed, and based on the analysis results, a more appropriate communication cycle is calculated and determined. The new communication cycle may be shortened (to cope with high load conditions) or extended (to save resources or reduce network burden); when determining the new cycle, the overall stability of the system and other potential factors are also considered to ensure that the adjusted communication cycle can meet the current needs without causing adverse effects on the system; After a new communication cycle is determined, the coupler updates its internal configuration and notifies all relevant IO modules and the master system.

[0074] It should be understood that the size of the serial numbers of the steps in the above embodiments does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0075] Those skilled in the art will clearly understand that for the sake of convenience and brevity of description, only the division of the above-mentioned functional units and modules is used as an example. In actual applications, the above-mentioned functions can be distributed and completed by different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above.

[0076] The embodiments described above are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, a person skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the protection scope of the present application.

Claims

1. A coupler system based on MECHATROLINK-Ⅲ, characterized in that: The coupler system includes a MECHATROLINK-Ⅲ master station, a MECHATROLINK-Ⅲ dedicated cable, a MECHATROLINK-Ⅲ coupler and a plurality of plug-in IO modules. The MECHATROLINK-Ⅲ coupler is used to manage all the plug-in IO modules in the slots to perform orderly IO input and output, and to undertake the communication interaction between the IO data of the entire coupler system and the MECHATROLINK-Ⅲ master station; The MECHATROLINK-Ⅲ coupler is integrated with a number of control units or execution units; Also includes: Data synchronization module, used to achieve time synchronization and traffic scheduling; A data redundancy check module is used to perform a cyclic redundancy check on the data packet; A dynamic bandwidth allocation module, for real-time monitoring and dynamically adjusting bandwidth allocation of the MECHATROLINK-III coupler according to operational requirements; Predictive data synchronization module, which is used to predict data synchronization needs by analyzing historical data and current status, and schedule resources in advance; The intelligent monitoring and feedback module is used to monitor the stability and synchronization of data transmission in real time, and trigger retransmission or error correction processes when an abnormality is found.

2. The MECHATROLINK-III-based coupler system according to claim 1, characterized in that: The dynamic bandwidth allocation module is used to monitor the communication load between the MECHATROLINK-Ⅲ master station and each of the plug-in IO modules in real time, and According to the communication load, determine the importance and urgency of the communication data, analyze and determine the priority of the data, and Based on the communication load condition and the priority of the data, the communication bandwidth allocated to each of the plug-in IO modules is dynamically adjusted.

3. The coupler system based on MECHATROLINK-Ⅲ according to claim 1, characterized in that: The predictive data synchronization module is used to monitor the operating status data of the MECHATROLINK-Ⅲ master station, coupler and plug-in IO module in real time, identify abnormal data, and Analyze the abnormal data using machine learning algorithms to predict the type and time of failure, and According to the fault type and time, a predefined fast recovery strategy is triggered.

4. The coupler system based on MECHATROLINK-III according to claim 1, characterized in that: The data synchronization module is used to control the time deviation between the MECHATROLINK-Ⅲ master station, MECHATROLINK-Ⅲ coupler and plug-in IO module within a predetermined range, and Scheduling communication traffic according to the real-time nature of data transmission and preset priority requirements, and Dynamically adjust network parameters and path selection.

5. The MECHATROLINK-III-based coupler system according to claim 1, characterized in that: The data redundancy check module is used to perform cyclic redundancy check calculation on the transmitted data packet, generate a check code and attach it to the data packet, and Performing the same cyclic redundancy check calculation on the received data packet at the receiving end and comparing it with the check code in the data packet to verify the integrity and correctness of the data, and When data errors are found, corresponding processing is performed according to the preset error handling strategy.

6. The MECHATROLINK-III-based coupler system according to claim 1, characterized in that: The intelligent monitoring and feedback module is used to monitor the stability index and synchronization status of the data transmission process in real time, and Analyze the monitored data according to the preset abnormal threshold, detect abnormal situations in data transmission, and When an abnormal situation is detected, a corresponding processing flow is triggered according to a preset feedback processing mechanism corresponding to the abnormal threshold.

7. A communication method based on the coupler system according to any one of claims 1 to 6, characterized in that: The communication method comprises: S1. The MECHATROLINK-Ⅲ coupler starts self-test and scans all slots of the MECHATROLINK-Ⅲ coupler to determine the slot with the plug-in IO module; S2, forming a configuration book according to the plug-in IO modules scanned in S1, wherein the configuration book is stored in the memory of the MECHATROLINK-Ⅲ coupler in the form of a structure array; S3, the MECHATROLINK-III coupler starts initialization of the MECHATROLINK-III communication module, so that the MECHATROLINK-III coupler enters the MECHATROLINK-III slave station communication state; S4, the MECHATROLINK-III coupler reads the input data X1-Xm of each plug-in IO module in the configuration book stored in the memory in the order of slot numbers from small to large; S5, storing the input data X1-Xm read in S4 in a preset SendBuff in order, and sending the input data X1-Xm to the MECHATROLINK-Ⅲ master station when a read instruction from the MECHATROLINK-Ⅲ master station arrives; S6, the MECHATROLINK-Ⅲ coupler obtains the output data Y1~Yn received from the MECHATROLINK-Ⅲ master station within the specified time according to the instruction received from the MECHATROLINK-Ⅲ master station; S7, the MECHATROLINK-III coupler outputs data Y1-Yn to each plug-in IO module in the configuration book according to the slot number in ascending order according to the configuration book stored in the memory; S8, the MECHATROLINK-Ⅲ coupler detects the error status of each plug-in IO module in the configuration book every 100 ms, and reports the status of each plug-in IO module in the configuration book to the MECHATROLINK-Ⅲ master station; S9. Repeat steps S3 to S8.

8. The communication method of the coupler system based on MECHATROLINK-Ⅲ according to claim 7, characterized in that: The step of storing the input data X1-Xm read in S4 in sequence into a preset SendBuff includes: The input data X1-Xm are encoded using a preset compression algorithm to generate compressed data, and the compressed data are stored in a preset SendBuff in sequence.

9. The communication method of the coupler system based on MECHATROLINK-Ⅲ according to claim 7, characterized in that: After step S8, the communication method further includes: S81, monitoring the workload and communication requirements of the MECHATROLINK-III coupler and the plug-in IO module; S82. Analyze the rationality of the current communication cycle according to the monitoring results. If the current communication cycle cannot meet the workload and communication requirements, calculate and determine a new communication cycle.

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