Interlocking DEC Modules for Shared Industrial Machine Data Buses
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Solution Overview
Problem
Existing methods for collecting and communicating machine data from industrial machines require manual human intervention, which is time-consuming and inefficient, and existing communication technologies face challenges such as limited wireless communication, noise interference, and the lack of standardized protocols.
Innovation Solution
The implementation of data extraction and communication (DEC) modules that utilize interlocking transceiver devices with half-duplex and full-duplex architectures, along with a multi-manager token (MMT) line, allowing devices to dynamically assume manager or worker roles, and share communication lines, enabling efficient data transfer and firmware updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual human intervention is used to collect and communicate machine data, then data collection can be performed with simple hardware, but the process becomes time-consuming and inefficient
Solution Approach 1:
The system enables automated data collection where the industrial machine itself generates and transmits operational data through integrated sensors and communication modules, eliminating the need for manual data gathering by operators
Solution Approach 2:
Manual mechanical data collection methods are replaced with electronic automation systems including microcontrollers, sensors, and wireless communication modules that automatically capture and transmit machine operational data
2Ease of operation
If wireless communication is used for data transmission, then wiring is minimized, but communication reliability is reduced due to limited range and noise interference
Solution Approach 1:
A dual-mode communication system acts as an intermediary, offering both wireless and wired communication options. The system can automatically select or switch between modes based on environmental conditions, ensuring reliable data transmission while maintaining ease of installation
Solution Approach 2:
The communication system dynamically adjusts transmission parameters such as frequency, power level, and protocol selection based on detected noise levels and signal quality, optimizing reliability for varying industrial environments
3Adaptability or versatility
If standardized communication protocols are implemented, then device compatibility is improved, but system complexity increases due to protocol implementation requirements
Solution Approach 1:
The system implements multiple standardized communication protocols (Modbus RTU, Modbus TCP, HTTP, MQTT) within a single unified platform, allowing one device to communicate with various different systems and protocols without requiring separate hardware for each protocol
Solution Approach 2:
The system uses software-based protocol implementations that can be configured and loaded as needed, rather than hardwiring specific protocols into hardware, allowing flexible protocol selection without increasing physical system complexity
4Extent of automation
If automated data collection systems are implemented, then manual intervention is reduced, but system complexity and cost increase
Solution Approach 1:
The automated system is divided into modular functional components including sensor modules, processing units, communication interfaces, and power management sections. Each module performs a specific function and can be independently configured or replaced, reducing overall system complexity
Solution Approach 2:
A single integrated controller performs multiple functions including data acquisition, processing, storage, and transmission through various protocols, eliminating the need for separate dedicated components for each function and thereby reducing system complexity
Data Source
AI summary
Devices, such as sensors, can interface with industrial machines and/or the industrial machine computers or sensors, and can extract or obtain machine operation data. Devices can communicate the machine data, via a communication bus, using hardware and software-based communication protocol. Efficiencies can be realized when the devices share the same communication bus and can communicate with one another, by assuming manager or worker status, interchangeably. The devices can include a mechanical and electrical architecture that allows them to daisy chain connect, by mechanically and electrically interlocking with one another in a vertical or horizontal stack, forming the communication bus, shared between a plurality of devices.