I/O Interface Module Serializes Discrete Signals for Pump Controllers
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Solution Overview
Problem
Current pump systems face challenges in interfacing pump controllers with various devices due to different physical interfaces and signaling schemes, leading to complex wiring and limited I/O line lengths, which can result in inefficient fluid dispensing and increased costs in semiconductor manufacturing.
Innovation Solution
The implementation of an I/O interface module with customizable data communications interfaces that can connect to multiple devices and pump controllers, allowing for serial packetization of data over a high-speed SPI bus, reducing the need for discrete lines and enabling longer connections while maintaining adaptability and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete I/O lines are used to interface pump controller with control devices, then each device can communicate with the pump controller, but the wiring becomes complicated and I/O line length is limited
Solution Approach 1:
The patent introduces an I/O interface module as an intermediary device between the pump controller and control devices. This module serializes multiple discrete I/O signals into a compact serial communication format, eliminating the need for numerous discrete wire connections. The interface module handles signal conversion and protocol management, allowing multiple devices to communicate through a single serial bus while maintaining full I/O functionality.
Solution Approach 2:
The patent replaces the mechanical/discrete wiring system with an electronic serial communication system. Instead of using physical discrete I/O lines that require individual wire connections, the system uses digital serial packets transmitted over a high-speed bus. This substitution dramatically reduces physical wiring complexity while maintaining all necessary communication capabilities.
2Reliability
If discrete I/O lines are used for communication, then direct control signals can be transmitted, but the I/O line length is limited
Solution Approach 1:
The patent replaces discrete electrical I/O lines with a serial digital communication system that can transmit data over longer distances with better signal integrity. The serial packet format includes error detection and correction capabilities, allowing reliable communication over extended cable lengths without the signal degradation issues inherent in discrete parallel I/O lines.
3Manufacturing precision
If custom interfaces are implemented for each control device, then precise control is achieved, but the pump controller must be customized for each interface
Solution Approach 1:
The patent implements a universal I/O interface module that can handle multiple different control device interfaces through a single standardized serial communication protocol. The interface module includes programmable functionality that can be configured to work with various control devices without requiring custom pump controller hardware for each device type. This universal approach maintains precise control capabilities while eliminating the need for pump controller customization.
Data Source
AI summary
Embodiments of the present invention provide I/O systems, methods, and devices for interfacing pump controller(s) with control device(s) which may have different interfaces and/or signaling formats. In one embodiment, an I/O interface module comprises a processor, a memory, and at least two data communications interfaces for communicating with a pumping controller and a control device. The I/O interface module can receive discrete signals from the control device, interpret them accordingly and send the packets to the pump controller. The pump controller reads the packets and takes appropriate actions at the pump. The I/O interface module can interpret packets of data received from the pump controller and assert corresponding discrete signals to the control device. The I/O interface module is customizable and allows a variety of interfaces and control schemes to be implemented with a particular multiple stage pump without changing the hardware of the pump.