Modular Control Board for Automatic Component Replacement
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Solution Overview
Problem
Conventional techniques for replacing discontinued electronic components on printed circuit boards are limited to programmable devices and do not address the need for replacing processors or programmable devices, which are essential for controlling the entire product.
Innovation Solution
A general-purpose control board with a processor and programmable device that can be mounted on multiple specific boards, incorporating pre-configured functional logics for various components, allowing automatic determination and control of alternative components, and supporting efficient manufacturing even when standard components are unavailable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional technique using a programmable device is used to replace a discontinued electronic component, then the component can be replaced, but the processor or programmable device that controls the entire product becomes unavailable
Solution Approach 1:
The control board is designed with universal compatibility to work with multiple types of specific boards (first specific board and second specific board). The processor is configured to execute applications that can operate different types of specific boards, enabling the same control board to replace discontinued components across multiple product lines without requiring unavailable processors or programmable devices.
2Ease of operation
If a processor executes a first application to control the apparatus, then the user interface and apparatus function are realized, but the programmable device needs to incorporate a second application to operate the specific board
Solution Approach 1:
The control system is divided into two functional segments: a first application executed by the processor that handles user interface control and apparatus-level functions, and a second application incorporated by the programmable device that handles specific board operations. This segmentation allows each component to focus on its specific function, simplifying the overall system architecture while maintaining ease of operation.
3Adaptability or versatility
If the general-purpose control board is mounted on both first and second specific boards, then component replacement across multiple apparatuses is enabled, but the manufacturing process becomes more complex
Solution Approach 1:
The control board is pre-configured with the necessary interfaces and applications to be compatible with both the first specific board and the second specific board before manufacturing. The processor is pre-programmed with the ability to execute applications for different specific board types, eliminating the need for complex post-manufacturing configuration or rework, thus simplifying the manufacturing process while maintaining versatility.
Data Source
AI summary
A general-purpose control board includes a core module and an expansion module such that a product can be manufactured efficiently even if a component mounted on a product-specific printed circuit board is replaced with an alternative component. A CPU of the core module includes a program that realizes cumulative specifications required to control a plurality of products anticipated in advance. A plurality of functional logics that control sensor circuits and motor circuits from a plurality of manufacturers, which are mounted for each apparatus, are implemented in FPGAs mounted on the core module and the expansion module. The CPU automatically determines which manufacturer's sensor circuit and/or motor circuit have been mounted, and notifies FPGAs of the determination result, to select and use one of the plurality of functional logics implemented in the FPGAs.