Bus System With PoE Detection Circuit
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Solution Overview
Problem
Industrial automation networks face challenges in cost-effective wiring due to the need for separate power and data lines, with Power over Ethernet (PoE) systems requiring additional wiring for second power supplies, and devices without PoE functionality risk damage from supply voltage applied to communication components.
Innovation Solution
A bus system with a data cable and input/output module that uses a microcontroller unit to detect the presence of a communication subscriber, ensuring DC voltage is only applied if the remote module supports it, using inductive and capacitive assemblies to transmit both differential data signals and DC voltages over a four-wire data cable, allowing for safe connection of modules with or without PoE functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If Power over Ethernet (PoE) standard is used to transmit supply voltage via four-wire data line, then wiring complexity is reduced, but additional wiring is still required for second power supply
Solution Approach 1:
The patent combines two separate power supply functions (first power supply for sensors/control and second power supply for actuators) into a single four-wire data cable infrastructure. By using both wire pairs of the Ethernet cable, the system transmits two differential data signals and two DC voltages simultaneously, eliminating the need for separate power cables and reducing overall wiring complexity.
Solution Approach 2:
The four-wire data cable is designed to serve multiple functions simultaneously: it transmits two differential data signals for communication and provides two separate DC voltage supplies for different device components. This multi-functional approach allows a single cable to replace what would traditionally require separate data and power cables, reducing wiring quantity.
2Use of energy by moving object
If DC voltage is applied to electrical contacts via data cable, then power transmission is achieved, but non-PoE devices risk damage from voltage applied to communication components
Solution Approach 1:
The microcontroller unit performs a preliminary communication check with the remote device before applying DC voltage through the inductive assembly. By first establishing communication and detecting PoE capability, the system determines whether the remote device can safely receive power, preventing voltage application to non-PoE devices that would lack proper protection circuitry.
Solution Approach 2:
The system uses feedback from the communication channel to determine whether to activate the power transmission function. The microcontroller unit monitors communication status and device capability information, then adjusts the switching element accordingly - enabling voltage transmission only when the remote device confirms PoE support, thereby preventing damage to incompatible devices.
3Ease of operation
If separate power supply lines are laid for actuators and sensors, then independent power control is achieved, but wiring costs and complexity increase
Solution Approach 1:
The patent merges separate power supply lines for actuators and sensors into a single four-wire data cable. By utilizing both wire pairs, the system provides two independent DC voltage supplies (first and second power supplies) through the same physical infrastructure, maintaining independent power control capability while eliminating the need for separate power cables.
Solution Approach 2:
The system transitions from spatial separation (separate cables running parallel) to functional separation within the same medium (different wire pairs within the same cable). Each wire pair independently carries its own data signal and power voltage, enabling independent control of actuator and sensor power supplies without requiring physically separate cable paths.
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 solution enables efficient and safe transmission of both data and power over a single wiring, preventing damage to non-PoE devices and ensuring independent actuator and sensor power supplies, reducing system costs and complexity.
Implementation Method 1
the physical interface is connected to the respective electrical contacts of the two of the four second electrical contact elements via the first transformer and via the first capacitive assembly in order to apply a first differential data signal to the two electrical contacts of the two of the four second electrical contact elements
Implementation Method 2
the physical interface is connected to the respective electrical contacts of the two others of the four second electrical contact elements via the second transformer and via the second capacitive assembly in order to apply a second differential data signal to the two electrical contacts of the two others of the four second electrical contact elements
Implementation Method 3
the first DC voltage supply is connected to a respective electrical contact of two of the four second electrical contact elements via the first inductive assembly
Implementation Method 4
the second DC voltage supply is connected to a respective electrical contact of two others of the four second electrical contact elements via the second inductive assembly
Implementation Method 5
the microcontroller unit is configured to communicate with the communication subscriber of the data cable
Data Source
AI summary
A microcontroller unit of an input/output module checks whether a communication connection can be set up from the microcontroller unit to a communication subscriber of a data cable plugged into the one portion of a electrical plug connection of the input/output module, wherein the microcontroller unit of the input/output module actuates DC voltage supplies of the input/output module such that the DC voltage supplies apply a respective DC voltage to applicable electrical contacts of electrical contact elements of the input/output module only if the check has revealed that a communication connection has been able to be set up to the communication subscriber of the data cable.