Integrated Device Control Unit for Multi-Axis Machine Wiring
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Solution Overview
Problem
Existing multi-axis control systems for machines with electrically operated axes suffer from high wiring complexity, increased maintenance costs, and limited data transmission capacity due to the need for extensive clock and bus line wiring, leading to operational reliability issues and increased manufacturing costs.
Innovation Solution
A compact, pre-wired device integrating NC and PLC functionality, with a programmable logic-based device control means that eliminates the need for external clock lines and fieldbus systems, utilizing internal wiring for communication between modules and providing synchronous operation across power and control sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If decentralized instances are connected via clock lines and fieldbus systems, then multi-axis control functionality is achieved, but wiring complexity increases significantly
Solution Approach 1:
The patent merges the clock generator and fieldbus interface functions into the central control unit, eliminating the need for separate clock lines and reducing fieldbus wiring. Each axis control unit receives synchronized clock signals and communication data through integrated interfaces rather than dedicated external wiring, significantly reducing overall wiring complexity while maintaining multi-axis control functionality.
Solution Approach 2:
The central control unit is designed with universal interfaces that can handle multiple functions: generating clock signals, transmitting control data, and receiving feedback through the same physical connections. This multi-functionality allows a single wiring harness to replace what would traditionally require separate dedicated lines for clock synchronization and fieldbus communication.
2Adaptability or versatility
If extensive wiring is used for clock and bus lines, then decentralized control is achieved, but operational reliability decreases due to increased failure risk
Solution Approach 1:
By combining multiple signal transmission functions into integrated interfaces, the patent reduces the total number of connection points and wiring paths. Fewer physical connections mean fewer potential failure points, thereby improving operational reliability while maintaining decentralized control capability.
Solution Approach 2:
The patent extracts the clock generation function from individual axis units and centralizes it in the main control unit. This eliminates the need for each axis to have its own clock generator and associated wiring, reducing the overall wiring network and consequently the risk of wiring-related failures.
3Loss of information
If fieldbus transmission is used for communication, then data can be transmitted between modules, but data transmission capacity is limited by line length
Solution Approach 1:
The patent combines high-speed digital communication capabilities directly within the integrated circuit architecture of the control units. This internal digital communication pathway bypasses the limitations of external fieldbus transmission and line length constraints, enabling high-capacity data transmission between the central control unit and axis control units regardless of physical distance.
4Adaptability or versatility
If decentralized instances with separate clock generators are used, then each axis can be controlled independently, but manufacturing costs increase due to additional components
Solution Approach 1:
The patent extracts the clock generation function from individual axis control units and consolidates it into a single central clock generator in the main control unit. This eliminates the need for multiple separate clock generator components across different axis units, reducing component count and manufacturing costs while preserving independent axis control through software-based synchronization.
Solution Approach 2:
The central clock generator is designed with universal output interfaces that can synchronize multiple axis control units simultaneously. This single multi-functional component replaces what would traditionally require multiple separate clock generators, reducing manufacturing complexity and cost while maintaining the ability to control each axis independently through programmable control logic.
Data Source
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AI summary
The device has a power module (1) for supplying an axle drive with an electric energy, an axial regulating module (2) for regulating an axial specific characteristic, and an axial control module (4) controls the axle drive. The modules are interconnected with each other within the device as an internal component of the device. A programming logic is realized by a device control unit (5), which is covered by one of the modules. An addition communication is realized between the modules by the device control unit. An independent claim is also included for a method for operating a machine operating device.