Hot-Swappable I/O Module Carriers for Daisy-Chain Continuity
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Solution Overview
Problem
Existing flexible expandable automation systems face issues with daisy chain interruption when an I/O unit is unplugged, and require system reset or power down for I/O unit exchanges, which is time-consuming and laborious.
Innovation Solution
The automation device incorporates an I/O-module carrier with a hot-swap control unit that automatically bridges the interrupted daisy chain upon unplugging an I/O unit, allowing for hot-swappable I/O units without system reset or power down.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an I/O unit is unplugged from the daisy chain, then the daisy chain is interrupted and communication fails, but if a hot-swap control unit is added to automatically bridge the chain, then device complexity increases
Solution Approach 1:
The hot-swap control unit acts as an intermediary device that automatically detects when an I/O module is unplugged and bridges the daisy chain connection to maintain communication continuity. This mediator handles the complexity of chain interruption recovery, allowing standard I/O modules to be exchanged without system reset while preserving reliability.
Solution Approach 2:
The hot-swap control unit implements self-service by automatically detecting module removal, closing the daisy chain, and restoring communication without requiring manual intervention or system reset. This self-managing capability maintains reliability while reducing operational complexity.
2Loss of time
If system reset or power down is required for I/O unit exchange, then exchange procedure becomes time-consuming and laborious, but if hot-swap functionality is implemented, then control unit complexity increases
Solution Approach 1:
The hot-swap control unit performs preliminary actions by pre-configuring the daisy chain bridging capability and automatically detecting module removal before exchange completion. This allows I/O units to be exchanged without system reset or power down, significantly reducing exchange time while the control unit manages the complexity of maintaining communication during the swap.
3Ease of operation
If the daisy chain is manually reconfigured after I/O unit removal, then operational continuity is maintained, but ease of operation decreases due to manual intervention requirements
Solution Approach 1:
The hot-swap control unit provides self-service by automatically detecting when an I/O module is unplugged and actively closing the daisy chain connection. This eliminates the need for manual reconfiguration while maintaining reliability, making I/O unit exchange simple and straightforward without requiring operator intervention for chain management.
Data Source
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AI summary
The invention is about a flexible expandable automation device (1), having a main control unit (2), having further at least two I/O-units (3, 4), said I/O-units (3, 4) being connected to the main control unit (2) and to each other via an I/O-bus (6), said I/O-bus (6) working according to the daisy-chain technique, wherein the I/O-bus (6) has a bus signal line (7) and a daisy-chain-control-line (8), wherein each I/O-unit (3, 4) has a daisy-chain-control-IN-port (21) which is configured to receive a daisy-chain-control-signal as daisy-chain-control-IN-signal (24) and a daisy-chain-control-OUT port (23) which is configured to deliver the daisy-chain-control-signal as daisy-chain-control-OUT-signal (25) to the next adjacent I/O-unit. Each I/O-unit (3, 4) has an I/O-module carrier (9) and a pluggable and unpluggable I/O-module (10), wherein the daisy-chain-control-IN-port (21) and the daisy-chain-control-OUT-port (23) are part of the I/O-module carrier (9), and each I/O-module-carrier (9) has a hot-swap-control unit (19), said hot-swap control unit (19) being configured, in case of an unplugged I/O-module (10), to automatically bridge the interrupted daisy chain.