Industrial I/O Mesh Architecture for Flexible Controller Pairing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial automation systems face challenges in providing a capitally efficient and modular construction-compatible solution for industrial automation, particularly in managing inputs and outputs, as existing systems are inflexible and require dedicated controllers for specific I/O modules and field devices.
Innovation Solution
A mesh architecture system for I/O modules that allows for two-way communication between field devices and controllers, enabling prefabricated and prewired I/O modules to connect geographically close field devices to appropriate controllers, with fault states configured at the channel level for fault handling, and using Ethernet technology for connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dedicated controller architecture is used for I/O modules, then system reliability is improved through dedicated control paths, but device complexity and capital cost increase due to requiring separate controllers for each I/O module
Solution Approach 1:
The patent implements a universal controller architecture where a single controller can serve multiple I/O modules through the mesh network. The controller is designed to communicate with any I/O module in the network, eliminating the need for dedicated controllers for each module. This multi-functional approach reduces the number of controllers required while maintaining system reliability through the redundant mesh communication paths.
2Stability of the object's composition
If traditional I/O system architecture is used, then system stability is improved through fixed connections, but adaptability deteriorates due to inability to easily reconfigure I/O assignments
Solution Approach 1:
The patent implements dynamic I/O assignment where controllers and I/O modules can be reconfigured at runtime through the mesh network. The system allows I/O channels to be dynamically assigned to different controllers based on operational needs, process conditions, or maintenance requirements. This dynamic reconfiguration capability provides adaptability while maintaining stability through the persistent mesh network connections and structured communication protocols.
3Ease of manufacture
If field junction boxes are used in traditional I/O systems, then ease of installation is improved through standardized connection points, but manufacturing efficiency deteriorates due to on-site assembly requirements
Solution Approach 1:
The patent extracts the I/O functionality from traditional field junction boxes and integrates it directly into the mesh network nodes. By eliminating the need for separate junction boxes and using the I/O modules themselves as the connection points in the mesh network, the system reduces on-site assembly requirements. The pre-configured mesh network modules can be directly installed and connected, eliminating the need for additional junction box installation while maintaining ease of connection through standardized mesh interfaces.
4Difficulty of detecting and measuring
If one-to-one controller to I/O module mapping is used, then fault isolation is improved through dedicated control paths, but loss of time increases due to inability to redistribute I/O loads during failures
Solution Approach 1:
The patent implements feedback mechanisms in the mesh network that continuously monitor communication status and controller health. When a fault is detected, the system automatically redistributes I/O assignments through the mesh network to healthy controllers. The feedback loop enables real-time detection of controller failures and automatic reconfiguration of I/O channels, maintaining system operation while isolating the faulty component. This feedback-driven dynamic reconfiguration reduces downtime while maintaining fault isolation through the mesh network's ability to identify and exclude failed nodes.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An industrial automation system employing a mesh topology of input/output allows flexibility in pairing field devices and controllers though the I/O mesh. Field devices can be connected to the geographically closest I/O module channel without regard to the location of the necessary controller. Modular prefabrication and deployment of the I/O modules becomes less complex and less time consuming thereby reducing costs.