Dual-Ring Automation Network for EtherCAT Error-Mode Communication
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Solution Overview
Problem
Existing automation networks with EtherCAT protocol face challenges in maintaining real-time communication and resilience when errors occur, particularly with the introduction of network distributors like switches or branches, which limit communication beyond areas with only slave subscribers.
Innovation Solution
The proposed automation network employs a dual ring structure with a master subscriber, switches, and slave subscribers, where two telegrams based on the same data packet are transmitted through different paths. This setup allows for error mode operation, where telegrams can be returned to the master subscriber even in the presence of line interference, ensuring communication with all network subscribers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundant data line network is used to reconnect the last slave subscriber to the master subscriber, then the master subscriber can address both upstream and downstream slave subscribers during error mode, but the communication cannot be maintained in areas with network distributors like switches or branches
Solution Approach 1:
The network is segmented into multiple independent dual-ring structures, each capable of autonomous error handling. The automation network is divided into first and second dual-ring structures that can operate independently, allowing error containment and localized recovery without affecting the entire network.
Solution Approach 2:
The patent introduces a third dimension to the traditional dual-ring structure by adding network distributors (switches or branches) that create multi-path communication routes. This dimensional expansion allows telegrams to bypass errors through alternative paths in the distributed network topology.
2Reliability
If two telegrams based on the same data packet are transmitted through different paths, then error mode operation is enabled with reduced telegram traffic and overhead, but the network structure becomes more complex
Solution Approach 1:
Multiple telegrams carrying the same data packet are merged into a single processed result at the destination. The master subscriber sends duplicate telegrams through different paths, and the network consolidates these redundant transmissions, achieving error protection without proportionally increasing overall communication overhead.
Solution Approach 2:
The network pre-configures redundant communication paths and duplicate telegram transmission before errors occur. This beforehand cushioning ensures that when line interference or errors happen, alternative paths are already established and ready for immediate use, maintaining real-time communication without reactive complexity.
3Adaptability or versatility
If network distributors like switches or branches are introduced to extend the network, then network versatility and coverage are improved, but communication cannot be operated in error mode beyond areas with only slave subscribers
Solution Approach 1:
Network distributors (switches or branches) are designed to perform multiple functions: normal data forwarding, error detection, and alternative path selection. These universal components can operate in both normal mode and error mode, enabling communication throughout the entire network regardless of topology or error location.
Solution Approach 2:
Network distributors act as intermediaries between the dual-ring structure and end devices. They mediate telegram routing by receiving telegrams from the ring structure and distributing them to connected devices, while also mediating error handling by detecting line interference and triggering alternative path selection.
Data Source
AI summary
An automation network comprises at least one primary subscriber, at least one switch, and at least one network subscriber. The primary subscriber comprises primary ports, the switch comprises switching ports, and the subscriber comprises subscriber ports, each comprising a transmitter and a receiver. The primary subscriber is configured to output first and second telegrams to first and second switching ports via first and second primary ports and first and second primary communication paths. The switch is configured to forward the first telegram to a first port of a network subscriber via a first subscriber communication path, and to forward the second telegram to a second port of a network subscriber via a second subscriber communication path. In an error mode, the switch and network subscriber are configured to return the first and/or second telegrams to the primary subscriber via the first and/or second primary port.