Integrated IO-Link Master with AC/DC Converter for High-Power Actuator Supply
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Solution Overview
Problem
IO-Link communication systems face limitations in providing sufficient electrical supply current for high-power actuators, such as drives and grippers, due to conventional plug specifications, leading to restricted simultaneous operation and increased installation complexities and energy consumption in industrial settings.
Innovation Solution
An integrated arrangement combining an AC/DC converter with an IO-Link communication interface and a gateway function, utilizing power electronics like SiC or GaN transistors, allows for efficient and flexible power supply to actuators, eliminating the need for separate voltage supply units and reducing cabling complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional plug connectors with maximum 9A current are used for IO-Link masters, then the device complexity and installation space are reduced, but the power supply capability for high-power actuators is insufficient
Solution Approach 1:
The patent combines the voltage supply unit (AC/DC converter) and the IO-Link communication interface into a single integrated arrangement. This merging allows the system to provide both high power supply capability (through the voltage supply unit) and communication functionality (through the IO-Link interface) without requiring separate devices, thus resolving the contradiction between power capability and device complexity
Solution Approach 2:
The integrated arrangement serves multiple functions simultaneously: it provides AC/DC conversion for power supply, enables IO-Link communication for control and monitoring, and offers unified diagnosis and parameterization. This multi-functionality eliminates the need for separate voltage supply units and communication interfaces, resolving the contradiction by achieving high power capability without proportionally increasing device complexity
2Power
If separate voltage supply units are used for high-power actuators, then the power supply capability is sufficient, but the installation space and cabling complexity increase
Solution Approach 1:
By merging the voltage supply unit and IO-Link communication interface into one compact integrated arrangement, the patent eliminates the need for separate voltage supply units. This integration significantly reduces the installation space required in control cabinets while maintaining sufficient power supply capability for multiple high-power actuators
Solution Approach 2:
The integrated arrangement provides multiple functions (power supply, communication, diagnosis) in a single device, reducing the overall number of components needed in the installation. This multi-functionality directly reduces the installation space while maintaining full power supply capability
3Productivity
If multiple separate voltage supply units are deployed for simultaneous actuator operation, then the power supply capability is sufficient, but the energy losses and installation costs increase
Solution Approach 1:
The patent merges multiple power supply functions into a single voltage supply unit within the integrated arrangement. This centralized approach allows multiple actuators to be powered simultaneously through one efficient AC/DC converter, reducing the total energy losses that would occur with multiple separate converters operating in parallel
Solution Approach 2:
The single integrated arrangement serves as a universal power and communication hub for multiple actuators, enabling simultaneous operation while consolidating energy conversion functions. This reduces redundant energy losses associated with multiple separate voltage supply units
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables simultaneous operation of multiple high-power actuators with reduced energy consumption, simplified installation, and enhanced spatial flexibility, while allowing for unified diagnosis and parameterization of actuators and voltage supplies, thereby minimizing switch cabinet requirements and energy losses.
Implementation Method 1
An integrated arrangement having an electrical voltage supply unit (AC/DC converter) as well as an IO-Link communication interface
Implementation Method 2
utilizing power electronics like SiC or GaN transistors, allows for efficient and flexible power supply to actuators
Data Source
AI summary
In an arrangement of an electrically communicative voltage supply for controlled operation of at least one electrically operable IO-Link device using an electrical DC voltage provided by a voltage supply unit as well as an IO-Link communication interface which is provided for the controlled operation of the at least one IO-Link device and formed with at least one channel, the IO-Link communication interface which is formed with at least one channel and the voltage supply unit form a structural unit and the IO-Link communication interface includes an IO-link master providing a gateway function.