Embedded Motor Controller Switch for Tiered Real-Time Communication
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Solution Overview
Problem
In motor drive applications, the increasing complexity and demand for real-time communication between various devices, including motors, sensors, and controllers, lead to resource burdens on motor controllers, which struggle with processing multiple communication protocols and managing different types of data effectively, resulting in inefficiencies and increased complexity.
Innovation Solution
An embedded switch within the motor controller implements a three-tier communication protocol to prioritize and manage data transmission based on deterministic, high-rate, and best-effort requirements, allowing for efficient communication between devices and reducing the need for extensive network cabling by enabling daisy chaining and bidirectional real-time communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If motor controllers process multiple communication protocols and manage different types of data directly, then communication functionality is comprehensive, but resource burden on motor controllers increases and system complexity increases
Solution Approach 1:
The patent segments the communication system into three distinct tiers: Tier 1 for deterministic real-time control data, Tier 2 for high-rate data, and Tier 3 for best-effort data. Each tier has dedicated communication resources and protocols, separating different data types and their requirements. This segmentation allows the motor controller to handle each tier independently, reducing the overall complexity burden while maintaining comprehensive communication functionality across all data types.
2Adaptability or versatility
If motor controllers process multiple communication protocols and manage different types of data directly, then communication functionality is comprehensive, but resource burden on motor controllers increases
Solution Approach 1:
The patent introduces communication switches as intermediary devices between the motor controller and various communication devices. These switches operate autonomously to manage data transmission within each tier, filtering and routing data packets without requiring the motor controller to process every protocol and data type directly. This intermediary layer offloads processing resources from the motor controller while maintaining comprehensive communication capabilities through the multi-tier architecture.
3Adaptability or versatility
If extensive network cabling is used to connect all devices, then communication coverage is complete, but network complexity and cost increase
Solution Approach 1:
The patent adds a hierarchical dimension to the network architecture by organizing devices into three communication tiers with different priorities and requirements. Instead of a flat network where all devices connect equally, the hierarchical structure allows devices to be grouped by their communication needs. This dimensional organization enables complete communication coverage while reducing network complexity, as devices only need to connect to switches appropriate for their tier rather than requiring full mesh connectivity.
4Manufacturing precision
If deterministic real-time control data is transmitted with highest priority, then control precision is improved, but bandwidth for other data types is reduced
Solution Approach 1:
The patent segments the available communication bandwidth into three separate channels corresponding to the three tiers. Tier 1 is allocated dedicated bandwidth for deterministic real-time control data, ensuring control precision without interference. Tier 2 receives high-rate data transmission capacity, and Tier 3 receives best-effort bandwidth. This segmentation allows deterministic control data to receive highest priority and guaranteed bandwidth allocation while still providing adequate bandwidth for other data types through the multi-channel structure.
Data Source
AI summary
The subject matter disclosed herein describes a switch embedded in a motor controller and a network protocol executing on the switch to provide communication between devices connected to the motor controller in a motor drive application. The embedded switch is configured to communicate via separate ports with an external controller, a network interface for the motor controller, additional motor controllers, and with the motor or other devices mounted on the motor. The network protocol includes a first tier for data that requires deterministic delivery at a high data rate, a second tier for data that requires a high delivery rate but is also tolerant of some variation in delivery time, and a third tier for data that may be delivered at a slower data rate. The embedded switch receives data at any port, identifies the communication tier to which the data belongs, and delivers it to another port accordingly.