IO-Link Signal Line Abnormality Detection Without Extra Hardware

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Solution Overview

Problem

Existing FA systems face challenges in detecting signal line abnormalities, such as disconnection and short circuits, without increasing hardware or costs, particularly for digital and analog signals, and struggle to accurately determine disconnections when measurement ranges include 0.

Innovation Solution

A control system that uses a communicator and signal receiver to determine signal line abnormalities based on data received and output signal values, employing software-based determiners to check for changes in binarized digital or analog signal values over predetermined times, and calculates differences between moving average values to detect anomalies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hardware such as leakage current detector and poly-switch is mounted to detect signal line abnormalities, then detection capability is improved, but device size and cost increase

Engineering Contradiction:

Improvesignal line abnormality detection capabilityVSAvoiddevice size and cost

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces hardware-based detection mechanisms (leakage current detectors, poly-switches) with a software-based determination unit that uses logical operations on data from existing communication and signal reception functions. This substitution eliminates the need for additional physical components while maintaining abnormality detection capability through comparative analysis of communicated data and received signal values.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The determination unit utilizes data and signals already present in the system's normal operation to perform self-diagnosis of signal line abnormalities. By comparing data received through the communicator with output signal values received through the signal receiver, the system monitors its own health without requiring external detection hardware.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If voltage threshold method is used to detect disconnection in analog signal lines, then detection is simple, but detection accuracy deteriorates when measurement range includes 0

Engineering Contradiction:

Improvedetection method simplicityVSAvoiddisconnection detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent introduces an intermediary comparison mechanism that uses data from the communication protocol as a reference to evaluate signal line status. Instead of directly comparing voltage thresholds that may be ambiguous near zero, the system uses the communicated data as an intermediary reference point to determine whether signal line abnormalities have occurred, improving accuracy while maintaining simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3242174B1Control system, control method, control program, and recording medium

Publication Date: 2022.06.01 OMRON CORP

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AI summary

Abnormality of a signal line is detected without enlarging a device or increasing cost. An IO-Link master includes: an IO-Link communication port that communicates with an IO-Link device according to a predetermined communication protocol; a digital input port that receives a first signal value output from the IO-Link device; and a determiner that determines whether abnormality is generated in a digital input line connecting the digital input port to the IO-Link device based on a second signal value received with the IO-Link communication port and the first signal value.