IO-Link Coupler States for Extended Cable Distance
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Solution Overview
Problem
Existing automation systems face challenges in establishing flexible and adaptable data connections between master and device units, particularly due to limitations in communication protocol distances and the limitations of common couplers, which restrict flexible use and lead to issues like latency and incorrect coupling processes.
Innovation Solution
A system with primary and secondary coupler units for wireless power and data transmission, allowing for three operating states that enable flexible and adaptable data connections according to the IO-Link standard, providing mechanical and galvanic isolation, and allowing the system to behave like an extended cable line, with coupler units being 'invisible' to the connected units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a direct data connection is established between master unit and device unit using common communication protocols, then data transmission is achieved, but the connection becomes unstable or unfeasible when cable length exceeds maximum permissible distance
Solution Approach 1:
The patent introduces an intermediate coupler unit that acts as a mediator between the master unit and device unit. This coupler receives data from one unit and transmits it to the other, enabling communication over extended distances that would exceed the maximum cable length specifications of standard IO-Link protocols. The intermediate unit effectively divides the communication path into two segments, each within acceptable distance limits.
Solution Approach 2:
The communication path is segmented into multiple sections by introducing the coupler unit. Instead of a single direct connection between master and device, the data path is divided into master-to-coupler and coupler-to-device segments. This segmentation allows each segment to remain within the maximum permissible cable length while achieving overall extended communication distance.
2Adaptability or versatility
If conventional couplers are used for data and power transmission, then coupling is achieved, but the coupling process becomes faulty and lacks flexibility in adapting to different application contexts
Solution Approach 1:
The coupler unit implements dynamic adaptation by detecting the operational state of connected devices and automatically adjusting its behavior accordingly. It can switch between different operating modes (e.g., power transmission mode, data transmission mode, or combined mode) based on real-time conditions, enabling flexible adaptation to various application contexts while maintaining reliable and correct coupling through automated state recognition.
Solution Approach 2:
The coupler unit is designed with multi-functionality to handle both data transmission and power transmission through the same interface. It can operate in different configurations depending on the connected devices, serving as a universal coupling solution that adapts to various application contexts rather than requiring separate specialized couplers for different functions.
3Ease of operation
If wireless coupling is implemented between primary and secondary coupler units, then mechanical and galvanic isolation is achieved, but system complexity increases
Solution Approach 1:
The patent replaces the mechanical cable connection between primary and secondary coupler units with a wireless communication link. This substitution eliminates the need for physical cable routing and connectors between the coupler units, achieving mechanical isolation and simplifying installation. The wireless connection (e.g., Bluetooth, Wi-Fi) maintains data transmission functionality without requiring direct physical contact or galvanic connection between the coupler 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 flexible and reliable data connections, reduces latency, and allows for easy adaptation to different application contexts, improving the system's flexibility and reliability by establishing stable IO-Link connections that would otherwise be unstable or unfeasible with direct coupling.
Implementation Method 1
Power transmission is achieved, in particular, by means of an inductive connection
Implementation Method 2
A data connection can be established, for example, via an inductive connection, near-field communication
Data Source
Figure 1~2C
Figure 3
AI summary
The invention relates to a system for establishing a data connection between a master unit (M) and at least one device unit (D), wherein the master unit (M) is coupled to a primary coupler unit (Dprim) and the at least one device unit (D) is coupled to a secondary coupler unit (Dsek), respectively, for electrical power transmission and data transmission. The primary coupler unit (Dprim) and the secondary coupler unit (Dsek) can be coupled for data transmission. A control signal is receivable, and the system has three operating states that can be activated depending on the received control signal. In the first activated operating state, a data connection conforming to the IO-Link standard exists between the master unit (M) and the device unit (D).In the activated second operating state, the primary coupler unit (Dprim) is assigned primary coupler identification data (Dprim ID), and a data connection conforming to the IO-Link standard exists between the master unit (M) and the primary coupler unit (Dprim). In the activated third operating state, the secondary coupler unit (Dsek) is assigned secondary coupler identification data (Dsek ID), and a data connection conforming to the IO-Link standard exists between the master unit (M) and the secondary coupler unit (Dsek). The invention further relates to a method for operating the system.