Distributed Control Hub With Offset Stacking and Protocol Conversion
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Solution Overview
Problem
Existing manufacturing facilities face challenges in integrating diverse actuators and sensors with different communication protocols, requiring manual data input and separate control systems, which complicates overall production management.
Innovation Solution
A stackable distributed communication and control hub (DCCH) with offset brackets for wide viewing angles, dynamically reconfigurable connection ports, and in-line signal processing devices for automatic protocol conversion, enabling seamless integration of edge devices with different communication protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate control systems are used for different actuators and sensors with different communication protocols, then each device can be controlled independently, but the overall system complexity increases and manual data input is required
Solution Approach 1:
The control hub is designed with multiple connection ports that can dynamically adapt to different communication protocols (Modbus, Profibus, Profinet, Ethernet IP, etc.), allowing a single device to perform multiple protocol conversion functions rather than requiring separate control systems for each protocol
Solution Approach 2:
The control hub acts as an intermediary device between various actuators and sensors with different protocols and the central control system, automatically translating and converting communication protocols to enable seamless integration without manual data input
2Area of stationary object
If multiple DCCHs are stacked vertically for compact installation, then space is saved, but the viewing angle for inspecting connection ports is limited
Solution Approach 1:
The offset bracket creates an asymmetric arrangement where the second DCCH is positioned at an offset from the first DCCH, shifting the connection ports to different vertical levels and enabling a wider viewing angle for inspection while maintaining compact vertical stacking
Solution Approach 2:
The offset bracket introduces a horizontal dimension to the vertical stacking arrangement, creating a three-dimensional offset configuration that separates connection ports spatially in both vertical and horizontal directions, improving accessibility and viewing angle
3Adaptability or versatility
If manual data input is required to integrate devices into the control system, then integration can be performed, but time and labor are consumed
Solution Approach 1:
The control hub automatically performs protocol detection and configuration when devices are connected, eliminating the need for manual data input by enabling the system to self-configure communication parameters and integrate devices autonomously
Data Source
AI summary
Apparatus and associated methods relate to a stackable distributed communication and control hub (DCCH) configured to provide a wide viewing angle for instantly inspecting multiple connections when multiple DCCHs are stacked. In an illustrative example, a DCCH may include multiple connection ports distributed on one or more edge surfaces. An offset bracket, for example, may couple two DCCHs, each at a coupling surface of the corresponding DCCH. Upon coupling, the DCCHs are held at substantially parallel planes. For example, a first DCCH is offset from a second DCCH in two directions. In a first direction, respective planes are offset along a vertical axis by a predetermined first offset. In a second direction, the DCCHs are offset by a predetermined second offset, orthogonal to the first direction. Various embodiments may advantageously allow visual status of the connection ports visible in at least one viewing angle along the vertical axis.