Clamping Control Redundancy for Reliable Inductive Signal Transfer
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Solution Overview
Problem
Existing machine tools with inductive couplers face challenges in reliably transmitting safety-critical signals, such as the safe torque off (STO) signal, due to the shared transmission path for redundant controls, leading to increased risks of data packet loss and communication disruptions.
Innovation Solution
A machine tool design featuring a contactless data connection between the machine control and clamping device control via a coupling unit, utilizing at least two redundant microprocessors to verify and transmit process data independently, ensuring reliable communication by analyzing signals for errors and maintaining a safe operating mode until valid STO signals are received.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single transmission path via an inductive coupler is used for redundant controls, then device complexity is reduced, but reliability of data communication deteriorates due to increased risk of data packet loss affecting both controls simultaneously
Solution Approach 1:
The patent divides the single transmission path into two independent transmission paths between the machine control and the clamping device control. This segmentation allows each path to operate independently, so that a failure or data packet loss in one path does not affect the other path, thereby improving reliability while maintaining manageable system complexity
Solution Approach 2:
The patent introduces an intermediate evaluation unit that receives data packets from both transmission paths and evaluates them for consistency. This intermediary component coordinates the redundant paths, ensuring that only verified and consistent data are processed, which enhances reliability without significantly increasing overall system complexity
2Reliability
If redundant microprocessors with independent verification are implemented, then reliability of safety-critical signal transmission is improved, but device complexity increases due to additional hardware components
Solution Approach 1:
The control system is segmented into distinct functional units: a first microprocessor for receiving and evaluating data packets, a second microprocessor for independent verification, and an evaluation unit for coordinating between them. This segmentation allows each component to have a specific, simplified function, improving reliability through redundancy while keeping individual component complexity manageable
Solution Approach 2:
The patent implements a feedback mechanism where the evaluation unit continuously monitors and compares data from both microprocessors. When inconsistencies are detected, the system can request retransmission or activate safety protocols. This feedback loop ensures high reliability of safety-critical signals while maintaining a structured, manageable control architecture
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
Enhances data communication reliability by detecting and preventing errors, ensuring safe operation and preventing unintentional machine restarts or workpiece loosening through redundant microprocessor monitoring and control.
Implementation Method 1
the coupling unit provides a contactless data connection from the machine control to the clamping device control
Data Source
AI summary
It is already know from the prior art to provide machine tools with a clamping device, in which a portion of the control is transferred to the clamping device. This simplifies the connection to the available machine control and allows a simplified coupling of the clamping device to the machine tool. However, in spite of the inductive coupling between the machine control and the clamping device control, it is not ensured that process data sets reach their intended destination.This situation is addressed by the present invention in that a clamping device control is allocated to the clamping device, two redundant microprocessors are included, which analyze received process data sets independently of each other and, in the case of an error, transfer the clamping device into a safe state.