IO-Link Coupler Switching for Long-Range Isolated Data Links
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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 wire length and the inefficiency of conventional couplers, which can lead to erroneous coupling processes and latency issues.
Innovation Solution
A system utilizing primary and secondary coupler units for wireless power and data transmission, allowing for three operating states that enable flexible communication and isolation, effectively establishing an IO-Link connection by relaying signals through the coupler units, thus overcoming distance and latency limitations.
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 impossible when distance exceeds maximum permissible wire length
Solution Approach 1:
The patent introduces coupler units as intermediary devices between the master unit and device unit. These couplers receive data from one unit, process it, and transmit it to the other unit, enabling communication over distances that exceed the maximum permissible wire length for direct connections while maintaining connection stability.
2Adaptability or versatility
If conventional couplers are used for data and power transmission, then coupling is achieved, but erroneous coupling processes occur and configurability is limited
Solution Approach 1:
The coupler units feature dynamically switchable operating states that can be activated by control signals. The system can switch between different coupling modes (e.g., direct coupling, isolated coupling, power transmission only, data transmission only), allowing adaptive response to different operational requirements while preventing erroneous coupling through state validation.
Solution Approach 2:
The coupler units incorporate feedback mechanisms that monitor the coupling state and provide status information to the master unit and device unit. This feedback enables the system to detect and prevent erroneous coupling attempts, ensuring reliable and accurate coupling operations.
3Ease of operation
If mechanical connection is used between master unit and device unit, then direct data transmission is achieved, but wear occurs and flexible decoupling is difficult
Solution Approach 1:
The patent replaces direct mechanical connections with wireless communication between coupler units. The master unit and device unit connect to couplers via wired connections, while the couplers communicate wirelessly with each other, eliminating mechanical wear at the master-device interface and enabling flexible decoupling without physical disconnection.
4Length of stationary object
If coupler units are introduced for extended range communication, then distance limitation is overcome, but system complexity increases
Solution Approach 1:
The coupler units are designed as multi-functional devices that can perform both data transmission and power transmission, as well as provide mechanical and galvanic isolation. By consolidating multiple functions into single coupler units, the patent extends communication distance without proportionally increasing system complexity.
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
The system enables flexible and reliable data connections, achieving mechanical and galvanic isolation, and allowing for direct communication between master and device units, even in scenarios where direct connections would be unstable or impossible, while providing enhanced configurability and error prevention.
Implementation Method 1
The coupling of the primary and secondary coupler units for power and/or data transmission can in particular be effected wirelessly. A data connection can be established, for example, via an inductive coupling, near-field communication, Bluetooth or Wi-Fi.
Implementation Method 2
A power transmission is obtained in particular by means of an inductive coupling.
Data Source
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 (Dsec), in each case for electrical power transmission and for data transmission. The primary coupler unit (Dprim) and the secondary coupler unit (Dsec) can be coupled for data transmission. A control signal can be received and the system has three operating states that can be activated in dependence on the received control signal. When the first operating state is activated, there is a data connection according to the IO-Link standard between the master unit (M) and the device unit (D). When the second operating state is activated, primary coupler identification data (Dprim-ID) are allocated to the primary coupler unit (Dprim), wherein there is a data connection according to the IO-Link standard between the master unit (M) and the primary coupler unit (Dprim). When the third operating state is activated, secondary coupler Identification date (DsecID) are allocated to the secondary coupler unit (Dsec), wherein there is a data connection according to the IO-Link standard between the master unit (M) and the secondary coupler unit (Dsec). The invention furthermore relates to a method for operating the system.