Black Channel Data Transmission for Encoder Reliability
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Solution Overview
Problem
Existing methods for data transmission between an encoder and a motor control unit or actuator control unit face challenges such as increased complexity and error frequency due to the need for extensive data integrity checks across insecure channels, leading to delayed response times and inefficiencies.
Innovation Solution
Implementing a 'black channel' approach where an insecure data transmission path is overlaid with an additional security layer, using independent position data and security features like CRC and life counters, which are evaluated only at the output by a secure evaluation unit to ensure data integrity and security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data integrity checks are performed over the entire transmission path using redundant channels, then data reliability is improved, but device complexity and effort increase significantly
Solution Approach 1:
The transmission path is segmented into a first half and a second half, with data transmitted in opposite directions on the same physical channel. Each direction transmits half of the total data volume, reducing the burden on any single transmission path while maintaining overall data integrity through cross-verification at the receiver.
Solution Approach 2:
A control unit acts as an intermediary that receives data from both transmission directions, performs integrity verification by comparing the two data sets, and coordinates the transmission process. This central mediator simplifies the overall system architecture compared to distributed verification approaches.
2Reliability
If serial cascaded processing units transmit data in separate cycles, then data transmission reliability is improved through quality checks, but data transmission time increases significantly
Solution Approach 1:
Data transmission occurs in periodic cycles with alternating directions. The first cycle transmits data in one direction, the second cycle transmits data in the opposite direction, creating a rhythmic transmission pattern that maintains reliability through structured verification while reducing total transmission time through parallel processing of opposite-direction data.
Solution Approach 2:
The system performs preliminary actions by transmitting half of the data volume in advance during the first cycle, then completes the transmission in the second cycle. This staged approach allows for intermediate verification points without requiring the entire data set to be transmitted sequentially, reducing overall transmission time.
3Reliability
If multiple transmission cycles are used for data verification, then data quality is improved, but response time is delayed
Solution Approach 1:
The transmission channel remains continuously active in both directions throughout the process. While one direction transmits data, the other direction simultaneously receives and verifies data, eliminating idle time and maintaining continuous useful action. This dual-directional continuous operation preserves data quality through verification while minimizing response time delays.
4Productivity
If position data is transmitted over long distances at high speed, then productivity is improved, but data integrity over insecure channels deteriorates
Solution Approach 1:
Two transmission directions are merged into a single physical channel, transmitting data simultaneously in opposite directions. This consolidation maintains high transmission speed by utilizing the full bandwidth of the channel while improving data integrity through the cross-verification of data received from both directions at the control unit.
Data Source
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AI summary
Method for data transmission between an encoder and a motor and/or actuator control unit via an unsafe multi-channel channel, wherein the multi-channel channel is configured as a black channel, which forms a non-safe transmission channel, which is checked by a superior or downstream instance, that the black channel with its non-safe protocol is superimposed by an additional safety protocol, and that the safety protocol transmits additional data about the transmission via the black channel to two independent evaluation units, which create verifiable redundancy that is evaluated in a downstream function block.