Distributed CNC I/O Synchronization Over Multipolar Cable
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Solution Overview
Problem
Existing data processing and transmission systems for machine tools are inflexible, bulky, and prone to noise, leading to inaccurate data synchronization and reliability issues, particularly in polluted environments where machine tools operate.
Innovation Solution
A modular data processing and transmission system utilizing a multipolar cable with a master unit and slave units, allowing for flexible configuration and reduced noise through synchronized clock signals and efficient data transmission, with slave units positioned close to devices to minimize cable length and noise, and a diagnostic block for monitoring power and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a centralized data processing system is used, then data processing capability is improved, but system flexibility and adaptability deteriorate
Solution Approach 1:
The system divides the data processing functionality into multiple independent processing units distributed throughout the machine tool. Each unit can process data locally and independently, allowing the system to be configured flexibly for different applications while maintaining strong data processing capabilities through parallel operation of multiple units.
2Productivity
If processing hardware is concentrated in a single apparatus, then data processing efficiency is improved, but system complexity and installation difficulty increase
Solution Approach 1:
The processing hardware is segmented into multiple distributed processing units rather than concentrated in a single apparatus. This reduces system complexity by breaking down the monolithic structure into manageable modules that can be installed and configured more easily, while maintaining processing efficiency through distributed parallel processing.
Solution Approach 2:
Processing units are placed locally near the devices they serve, reducing cable lengths and noise exposure. Each processing unit handles data locally, eliminating the need for complex long-distance cable connections while maintaining processing efficiency through distributed architecture.
3Adaptability or versatility
If devices are positioned in polluted environments, then operational flexibility is improved, but noise and measurement accuracy deteriorate
Solution Approach 1:
The vulnerable data processing and synchronization functions are extracted from the polluted environment and placed in protected processing units. The processing units are positioned close to devices in the polluted environment but maintain protected internal environments for sensitive electronics, effectively separating the processing function from the harmful external conditions.
Solution Approach 2:
Each processing unit creates a locally protected environment for sensitive electronics while allowing the machine tool to operate flexibly in polluted conditions. The processing units are designed with appropriate shielding and protection to maintain low noise levels internally while operating externally in harsh environments.
4Object-affected harmful factors
If cable length is reduced, then noise is reduced, but system adaptability and configuration flexibility deteriorate
Solution Approach 1:
The system is segmented into distributed processing units that can be independently positioned near their respective devices. This allows cable lengths to be minimized for each local connection while maintaining overall system flexibility through the modular nature of the distributed architecture. Each segment can be configured independently with short cables, yet the entire system remains highly adaptable.
Data Source
Figure 1~1A
Figure 1B
Figure 2
AI summary
A data processing and transmission system (1) for a numerical control unit (2) adapted to control a machine tool (3), comprises at least one input channel (4) adapted to a transit of operational signals from or to devices present in the machine tool, electronic circuits configured to process the operational signals to make available on an output interface (5) control signals for the numerical control unit, a multipolar cable (8) having a first and a second end, each provided with a multipolar connector (9), a master unit having the output interface, a main processor, a memory and at least one socket (7A) configured to be coupled to one of the multipolar connectors, one or more slave units (6), each provided with at least one external port (6A) defining the input channel, a memory, a secondary processor, and provided also with a first socket (6B) and a second socket (6C), configured to be coupled at least to a first or a second connector of the multipolar connectors in order to interconnect the slave unit at least with the master unit. The master unit has a clock and each slave unit has its own clock. The main processor of the master unit generates a synchronization signal and transmits it through the multipolar cable in order to synchronize all the clocks of the slave units with the clock of the master unit.