Modular IO-Link Communication Layout for Reduced Industrial Cabling
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Solution Overview
Problem
Conventional star-shaped arrangements of sensors and actuators in industrial systems, such as intralogistics systems, require complex and costly installations with numerous parallel data lines, leading to errors and inefficiencies.
Innovation Solution
A modular communication system with decentralized modules connected in a point-to-point structure, utilizing IO-Link technology and adaptable protocols, allows for efficient data transmission and expansion, reducing the need for long parallel lines and enabling cost-effective integration in large industrial plants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a star-shaped arrangement of sensors and actuators is used to connect distributed components to a central collection point, then all components can be centrally controlled and monitored, but a large number of long parallel data lines are required leading to complex and expensive installation
Solution Approach 1:
The system segments the data transmission path by introducing decentralized devices that act as intermediate nodes between the master unit and remote modules. Each decentralized device receives data signals from the master unit, processes them locally, and forwards relevant data to connected modules, thereby dividing the原本 centralized star topology into hierarchical segments that reduce cabling requirements
Solution Approach 2:
Decentralized devices serve as intermediary components between the master unit and remote modules. These intermediaries receive comprehensive data signals from the master unit, extract and process only the relevant data sets for their connected modules, and forward the processed data through point-to-point connections, eliminating the need for all modules to be directly connected to the master unit via separate long parallel lines
2Reliability
If multiple long parallel data lines are laid to connect remote modules to the master unit in a star configuration, then all modules can communicate with the master unit, but the installation becomes expensive and error-prone
Solution Approach 1:
Instead of having all modules directly connect to the master unit (traditional star topology), the system inverts the communication flow by having the master unit send data to decentralized devices, which then distribute the processed data to remote modules through simple point-to-point connections. This inversion transforms the complex many-to-many connection requirement into a hierarchical many-to-few-to-many structure
Solution Approach 2:
The decentralized devices extract and process only the relevant data sets from the comprehensive data signals received from the master unit. By taking out and processing data locally before forwarding it to specific modules, the system eliminates the need for long parallel data lines while maintaining communication reliability through reduced signal transmission distance and fewer connection points
3Adaptability or versatility
If data signals containing multiple data sets are transmitted through the system, then all modules can receive necessary information, but data transmission efficiency decreases due to the need to process and forward complete data signals
Solution Approach 1:
Each decentralized device performs local quality processing on the data signals by extracting and processing only the data sets relevant to its connected modules. This local processing approach allows the system to maintain comprehensive data distribution capability while improving transmission efficiency, as each intermediate device handles only the subset of data necessary for its local modules rather than forwarding complete unprocessed data signals throughout the entire network
Data Source
AI summary
A modular communication system for connection to a master unit, including a device which is configured in a decentralized manner and includes at least a first module and a second module, wherein the first module is configured and set up to be directly connected to the master unit, and wherein the second module is directly connected to the first module and is configured and set up to be indirectly connected to the master unit via the first module, wherein the first module is further configured and set up to receive a data signal from the master unit. The data signal includes at least a first data set usable by the first module, and at least a second data set usable by the second module. The present disclosure further relates to a summing frame method, to a block frame method and to an indexing method for operating the communication system.