Gateway Device Binary Signal Packing for Field Bus Overhead Reduction
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Solution Overview
Problem
Existing automation systems face limitations in data transmission due to high overhead bandwidth on primary high-speed Ethernet buses, restricting the number of information items that can be transmitted, especially when using protocols like CANopen and Profinet, which require significant overhead for each bit, limiting the process data size to 1028 bytes.
Innovation Solution
The method involves a gateway device that packs binary signals into data blocks of eight bits, converting them into byte format and transmitting these, along with analog signals in integer format, to reduce overhead and increase the number of information items that can be transmitted between field buses of different protocols, allowing for efficient communication between field devices and a superordinate control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If binary signals are transmitted individually using primary high-speed Ethernet bus protocol, then transmission reliability is maintained, but bandwidth overhead increases significantly (7 bits overhead per bit)
Solution Approach 1:
The patent combines multiple binary signals into single byte-format data blocks for transmission. Instead of transmitting each binary signal individually with separate protocol overhead, multiple signals are merged into compact data structures that utilize the full 8-bit byte capacity, thereby reducing total transmission overhead while maintaining data integrity through structured packing and unpacking operations at the gateway device.
Solution Approach 2:
The patent changes the data representation parameter from individual binary signals to packed byte-format data blocks. By transforming the data format from bit-level to byte-level organization, the system achieves more efficient utilization of the communication bandwidth while maintaining the ability to reliably transmit all original binary signal values through the gateway's packing and unpacking functionality.
2Device complexity
If process data size is limited to 1028 bytes due to CANopen protocol constraints, then communication simplicity is maintained, but the number of information items that can be transmitted is restricted
Solution Approach 1:
The patent segments the data transmission process into multiple stages: packing binary signals into byte blocks at the field device, transmitting compressed data through the gateway, and unpacking at the control unit. This segmentation allows the system to overcome the 1028-byte protocol limitation by organizing data efficiently in transit, thereby increasing the effective number of information items that can be communicated while maintaining protocol compatibility.
Solution Approach 2:
The patent introduces a new dimension of data organization by implementing byte-level packing of binary signals before transmission. This dimensional transformation from bit-level to byte-level data structure allows more information to be packed into the same transmission bandwidth, effectively increasing the quantity of transmittable information items without changing the underlying protocol constraints.
3Adaptability or versatility
If seven bits of overhead are provided for each bit transmitted, then protocol compatibility is maintained, but data traffic burden on the primary Ethernet bus increases
Solution Approach 1:
The patent merges multiple binary signals into single byte-format data blocks, reducing the number of separate transmission units. By combining multiple data elements into compact byte structures that are transmitted as unified units, the system maintains protocol compatibility at the byte level while dramatically reducing the total overhead burden on the Ethernet bus compared to transmitting each binary signal individually with full protocol overhead.
Solution Approach 2:
The patent changes the data transmission parameter from bit-level individual signals to byte-level packed blocks. This parameter transformation reduces the overhead ratio by organizing data in larger, more efficient units that better utilize the available bandwidth, thereby improving data traffic efficiency while maintaining compatibility with protocols that operate at the byte level.
Data Source
AI summary
Exemplary methods and systems are directed to transmitting a process map of a control or automation system via a gateway device. The gateway device includes at least one first functional unit connected to a higher-ranking control unit via a first communications link based on a primary field bus protocol, and at least one second functional unit connected to at least one field device via a second communications link based on a secondary field bus protocol. Binary signals are stored in corresponding registers and analog signals, which are in an integer format, are transmitted to the first functional unit such that the number of binary signals is reduced by packing the binary signals into data bytes. The data bytes are translated into corresponding telegrams that can be processed by the primary field bus protocol and with the analog signals are transmitted to the higher-ranking control unit.