I/O Unit Status Acquisition via Dedicated Terminals
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Solution Overview
Problem
Existing methods for acquiring status information from I/O units connected to a numerical controller reduce the amount of transmissible DI data and increase overall information transmission, relying on user programs and requiring time-consuming analysis.
Innovation Solution
A method that stores abnormality information within I/O units, notifies the numerical controller, and transmits status information separately from DI data, allowing for independent processing and prioritization of status information acquisition without relying on user programs, enabling efficient communication and rapid identification of abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If status information is transmitted using the same frame area as DI data, then status information can be acquired, but the amount of transmittable DI data is decreased
Solution Approach 1:
The patent divides the information transmission into separate channels: DI data and status information are transmitted through different communication paths. The I/O unit has dedicated status information output terminals that send status data independently from the main DI data frames, thus segmenting the information flow to avoid mutual interference and bandwidth contention.
Solution Approach 2:
The patent introduces an intermediary mechanism in the form of dedicated status information output terminals and a status information acquisition unit. This intermediary structure allows status information to be extracted and transmitted separately from the main data flow, acting as a mediator that resolves the conflict between status monitoring and data transmission bandwidth.
2Loss of information
If status information is acquired by analyzing every DI data, then status information can be collected, but it takes considerable time to recognize abnormality
Solution Approach 1:
The patent implements preliminary action by having the I/O unit pre-process and identify status information before transmission. The status information output unit proactively generates and transmits status data as soon as it becomes available, rather than waiting for periodic analysis of DI data frames. This preliminary preparation enables the numerical controller to receive ready-to-analyze status information immediately.
Solution Approach 2:
The patent establishes a feedback mechanism where status information is continuously monitored and transmitted back to the numerical controller in real-time. The controller receives status updates through dedicated terminals and can immediately respond to abnormality notifications, creating a closed-loop feedback system that reduces detection time compared to batch analysis methods.
3Reliability
If status information is acquired from all I/O units, then complete status monitoring is achieved, but the total amount of transmission increases
Solution Approach 1:
The patent applies local quality by enabling selective status information transmission based on the specific state of each I/O unit. Rather than all I/O units transmitting status information continuously, only those with relevant status changes or abnormalities transmit their data. This localized approach maintains monitoring completeness while reducing overall transmission volume and energy consumption.
Data Source
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AI summary
A method of acquiring status information of I/O units connected to a numerical controller capable of transmitting status information indicative of particulars of an abnormality occurred in any of the I/O units with less influence on an amount of transmittable information of input/output data. When an abnormality has occurred in the I/O unit, the I/O unit transmits an output signal with a status abnormality notifying bit set to a programmable controller (PC) in the numerical controller. The PC stores information indicative of I/O units in which the status abnormality has occurred as status-abnormality acquiring I/O unit information, in a storage device of the PC. The PC requests the status information to the I/O unit in which the abnormality has occurred according to the status-abnormality acquiring I/O unit information. In response to the request, the I/O unit transmits the status information to the PC.