Distributed Machine Tool I/O Network With PTP Clock Synchronization
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Solution Overview
Problem
Existing data processing and transmission systems for machine tools are inflexible, prone to noise interference, and have installation difficulties, leading to reduced accuracy and reliability in real-time data exchange and synchronization.
Innovation Solution
A modular data processing and transmission system using a multipolar cable network with a master unit and slave units, allowing for flexible configuration and reduced noise through proximity placement of slave units to devices, along with a synchronization method using the IEEE 1588 Precision Time Protocol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a centralized intelligence data processing system is used, then data processing capability is improved, but device flexibility and adaptability deteriorate due to predetermined dimensions and fixed number of ports
Solution Approach 1:
The centralized processing system is segmented into multiple distributed processing units (slave units) that can independently process data from connected devices. Each slave unit has its own processing capabilities, allowing the system to be scaled and configured flexibly by adding or removing units as needed, rather than being constrained by a fixed centralized architecture.
Solution Approach 2:
The system transitions from a single-dimension centralized architecture to a multi-dimensional distributed network architecture. Processing power is distributed across multiple spatial dimensions (different slave units at different locations), enabling both high processing capability and flexible adaptation to various application scenarios.
2Power
If a centralized intelligence data processing system is used, then data processing capability is improved, but installation difficulty increases due to high number of cables
Solution Approach 1:
Multiple communication and power connections are merged into a single cable system. The slave units communicate with each other and with the master unit through a daisy-chain cable connection, consolidating what would otherwise require multiple separate cables into one unified connection method, thereby simplifying installation.
3Reliability
If processing hardware is positioned far from devices, then control unit protection is improved, but noise interference increases reducing measurement accuracy
Solution Approach 1:
The processing function is segmented and distributed to slave units that can be positioned close to the measured devices in the polluted environment. This segmentation allows the master control unit to remain protected while the distributed slave units handle local data acquisition and preliminary processing, reducing the impact of distance-related noise interference.
4Adaptability or versatility
If distributed intelligence architecture is used, then system flexibility is improved, but data synchronization difficulty increases
Solution Approach 1:
The master unit implements a centralized coordination role that provides timing synchronization and data collection coordination to all slave units. This feedback mechanism ensures that despite the distributed architecture's flexibility, all units operate in a synchronized manner with proper timing relationships, eliminating the synchronization problems that would otherwise arise from distributed operation.
Data Source
AI summary
A data processing and transmission system (1) for a numerical control unit (2) adapted to control a machine tool (3), comprises at least one input channel (4) adapted to a transit of operational signals from or to devices present in the machine tool, electronic circuits configured to process the operational signals to make available on an output interface (5) control signals for the numerical control unit, a multipolar cable (8) having a first and a second end, each provided with a multipolar connector (9), a master unit having the output interface, a main processor, a memory and at least one socket (7A) configured to be coupled to one of the multipolar connectors, one or more slave units (6), each provided with at least one external port (6A) defining the input channel, a memory, a secondary processor, and provided also with a first socket (6B) and a second socket (6C), configured to be coupled at least to a first or a second connector of the multipolar connectors in order to interconnect the slave unit at least with the master unit. The master unit has a clock and each slave unit has its own clock. The main processor of the master unit generates a synchronization signal and transmits it through the multipolar cable in order to synchronize all the clocks of the slave units with the clock of the master unit.