Modular Building Automation Controller With Segmented Extension Units
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Solution Overview
Problem
Existing building automation systems face challenges in designing modular controller devices that are flexible, reliable, and adaptable to varying requirements, with issues such as resource wastage, high manufacturing costs, and difficulties in supply demand due to varying control network interfaces like DALI, sDIM, DMX, Modbus, BACnet, and KNX, while also needing automatic recovery from module malfunctions.
Innovation Solution
A modular controller device is designed with a base unit and extension units that attach to a common support structure, featuring separate power and communications buses, spring-loaded connectors for easy assembly, and a method for safe and organized communication and power management, allowing for plug-and-play operation and automatic recovery from module failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a controller device includes a large number of interfaces already to begin with, then it can meet various control needs, but it leads to large waste of resources and prohibitively high manufacturing cost
Solution Approach 1:
The controller device is divided into a base unit and multiple interchangeable extension units. Each extension unit provides specific control network interfaces (DALI, DMX, BACnet, KNX, etc.), allowing the system to be customized by combining the base unit with only the necessary extension units for each application, rather than including all interfaces in every device.
Solution Approach 2:
The base unit is designed with universal functionality including power supply, processing unit, memory, and a standardized mechanical interface that can accept different extension units. This universal base combined with specialized extensions resolves the contradiction between versatility and manufacturing cost.
2Adaptability or versatility
If dedicated controller device models are produced for all possible combinations of control needs, then specific requirements are met, but it results in difficulties in making supply meet demand
Solution Approach 1:
Instead of producing numerous dedicated models, the system segments controller functionality into a common base unit and separate extension units. This allows manufacturers to produce standardized base units in high volume and combine them with various extension units as needed, dramatically improving supply chain efficiency while maintaining the ability to meet specific customer requirements.
3Adaptability or versatility
If modules are added and removed frequently, then system flexibility is improved, but it may affect system reliability and communication stability
Solution Approach 1:
The system performs preliminary actions to ensure reliable communication before modules become operational. When an extension unit is attached, the base unit first establishes communication through the first communication bus, exchanges configuration information, and verifies proper connection before activating the module. This preliminary setup ensures that frequent module changes do not compromise system reliability.
Solution Approach 2:
The system implements feedback mechanisms where the base unit continuously monitors communication status and operational parameters of attached extension units. If communication issues or malfunctions are detected, the system can automatically adjust operations or isolate problematic modules, maintaining overall system reliability despite frequent configuration changes.
4Reliability
If one module becomes faulty, then system robustness is tested, but it may affect the operation of the rest of the system
Solution Approach 1:
The modular architecture segments the controller into independent functional units. If one extension unit becomes faulty, the failure is isolated to that specific module and does not propagate to other extension units or the base unit. The system can continue operating with the remaining functional modules, maintaining adaptability and operational continuity.
Solution Approach 2:
The system implements error detection and isolation mechanisms that cushion against failures. When a malfunction is detected in one module, the system automatically isolates that module from the communication buses and power distribution, preventing the fault from affecting other modules. This beforehand protection ensures system robustness and continuous operation of healthy modules.
Data Source
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AI summary
A base unit for a controller device of a building automation system comprises a mechanical interface (302) for attaching to a common mechanical support (105, 301), and an extension unit interface (110, 401). As parts of said extension unit interface (110, 401) are a power bus connector (402), a first communications bus connector (403), and a second communications bus connector (404). A power supply (207, 405) is coupled to said power bus connector (402) and configured to deliver electric power on a power bus (107) through said power bus connector (402). A first communications bus controller (406) is coupled to said first communications bus connector (403) and configured to set up and maintain communications on a first communications bus (108). A second communications bus controller (407) is coupled to said second communications bus connector (404) and configured to set up and maintain communications on a second communications bus (109) through said second communications bus connector (404).