Bus System With Isolated Channels For Power And Data
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Solution Overview
Problem
Industrial automation networks require separate energy supplies for actuators and sensors/controllers, leading to costly and complex cabling due to the need for dual cabling systems, which complicates achieving cost-effective and simple cabling solutions while ensuring safety and flexibility.
Innovation Solution
A bus system design that uses a four-wire data line to transmit two differential data signals and two DC-isolated voltages, employing transformers, inductive, and capacitive assemblies to isolate and manage the voltages, allowing for simultaneous data and power transmission over a single cabling system, enabling independent switching of actuator supplies without disrupting sensor and controller operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate energy supply lines are used for actuators and sensors/controllers, then safety and operational independence are improved, but cabling complexity and costs increase
Solution Approach 1:
The patent combines multiple energy supply lines and data transmission channels into a single bundled cable system. The cable contains multiple insulated conductors (e.g., 4-19 wires) that carry separate DC voltages and differential data signals, merging what would otherwise require multiple separate cabling systems into one integrated solution while maintaining electrical isolation between channels.
Solution Approach 2:
The cable is segmented into functionally independent channels, each with its own insulation and routing. Energy supply lines for actuators and sensors/controllers are separated within the bundle, along with data transmission pairs, allowing independent switching and fault isolation while physically consolidated in a single cable assembly.
2Device complexity
If Power over Ethernet is used to transmit voltage and data signals on the same data line, then cabling costs are reduced, but the ability to provide separate energy supplies for actuators and sensors/controllers is compromised
Solution Approach 1:
The cable system is divided into separate functional channels: dedicated DC voltage lines for power delivery and differential data signal pairs for communication. This segmentation allows PoE-style combined transmission while maintaining the ability to provide separate energy supplies to different device types through independently routed conductors within the same cable bundle.
Solution Approach 2:
The single cable system performs multiple functions simultaneously: it delivers DC power to both actuators and sensors/controllers through separate lines, transmits differential data signals bidirectionally, and maintains electrical isolation between channels. This multi-functionality replaces what would traditionally require separate power and data cabling systems.
3Device complexity
If a single cabling system is used for both data and power transmission, then cabling costs are reduced, but voltage interference and signal integrity issues may worsen
Solution Approach 1:
Insulation material acts as an intermediary between adjacent conductors and signal pairs within the cable bundle, providing electrical isolation that prevents voltage interference and ground loops. The insulation physically separates high-voltage power lines from low-voltage data lines, blocking harmful electromagnetic coupling while allowing close proximity for space efficiency.
Solution Approach 2:
Different regions of the cable have specialized properties: signal pairs are twisted together to reduce crosstalk, power lines have thicker insulation for voltage isolation, and shielding is applied selectively around sensitive data channels. This local differentiation of cable properties optimizes each channel for its specific function while maintaining overall integration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces cabling complexity and costs by using a single cabling system for both data and power, ensuring separate energy supplies for actuators and sensors/controllers, allowing for safe state transitions of actuators without interrupting communication, and supporting various bus topologies and protocols.
Implementation Method 1
a first transformer, a second transformer... The first channel of the data line connects the physical feed module interface to the physical consumer module interface via the first feed module transformer... and connects the first DC voltage source to the first consumer module DC voltage consumer
Implementation Method 2
a first inductive assembly, a second inductive assembly... connects the first DC voltage source to the first consumer module DC voltage consumer via the first inductive feed module assembly and the first inductive consumer module assembly, in order to transmit a first direct current
Implementation Method 3
a first capacitive assembly and a second capacitive assembly... The first channel of the data line connects the physical feed module interface to the physical consumer module interface via the first feed module transformer, the first capacitive feed module assembly, the first capacitive consumer module assembly
Data Source
AI summary
A bus system comprises a data line having a first channel with a first pair of wires and a second channel with a second pair of wires. The first channel connects a physical feed module interface to a physical consumer module interface and a first DC voltage source to a first consumer module DC voltage consumer, to transmit a first differential data signal between the feed module interface and the consumer module interface and a first direct current from the first DC voltage source to the first consumer module DC voltage consumer. The second channel connects the feed module interface to the consumer module interface and a second DC voltage source to a second consumer module DC voltage consumer, to transmit a second differential data signal between the feed module interface and the consumer module interface and a second direct current from the second DC voltage source to the second consumer module DC voltage consumer.