Universal Multiprotocol Industrial Data Logger Bi-directional Capture
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Solution Overview
Problem
Substrate processing systems face challenges in capturing and storing all data transmitted between components due to limited bandwidth and storage availability, leading to data loss as only portions are sampled or filtered, and existing systems are unable to handle both operational technology (OT) and information technology (IT) traffic types simultaneously.
Innovation Solution
A data capture module is introduced that monitors, compresses, and stores all data communicated between components of a substrate processing system using a data capture module with ports for bi-directional data forwarding, physical layer devices, MAC processing for timestamp insertion, and data compression protocols, ensuring real-time capture and storage without data loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If data is captured and stored in real-time without sampling or filtering, then data completeness is improved, but storage capacity is exceeded and bandwidth is insufficient
Solution Approach 1:
The patent extracts only the essential and relevant data from the complete data stream for storage, while allowing non-critical data to pass through without storage. This selective extraction approach maintains data completeness for important parameters while managing storage capacity constraints.
Solution Approach 2:
The system dynamically changes data capture parameters such as sampling rate, data retention duration, and compression level based on available storage capacity and bandwidth. When storage is full, the system adjusts parameters to prioritize critical data, thereby maintaining data completeness for essential measurements while adapting to storage constraints.
2Loss of information
If all data is captured and stored, then data completeness is improved, but system complexity increases
Solution Approach 1:
The patent segments the data capture system into multiple independent modules: a data capture module for receiving data, a data compression module for reducing data size, and a data storage module for saving compressed data. This segmentation allows each module to operate independently with optimized complexity, maintaining data completeness while managing overall system complexity through modular design.
Solution Approach 2:
The data compression module acts as an intermediary between the data capture module and the data storage module. It transforms raw data into a compressed format that is more efficient for storage, thereby reducing the burden on the storage system while maintaining data completeness. This intermediary layer simplifies the overall system architecture by handling the complex compression task in a dedicated component.
3Quantity of substance
If data compression is applied, then storage capacity utilization is improved, but data processing time increases
Solution Approach 1:
The system applies compression periodically or at specific intervals rather than continuously compressing every data point. Critical real-time data may be stored with minimal or no compression, while less time-sensitive data undergoes full compression. This periodic compression approach improves storage capacity utilization while minimizing the impact on data processing time for time-critical operations.
Data Source
AI summary
A data capture module includes a first port configured to receive first data transmitted from a first component to a second component of a substrate processing system, a second port configured to received second data transmitted from the second component to the first component, a first data stream forwarding module configured to duplicate the first data, forward the duplicated first data to the second port, and output the first data, and a second data stream forwarding module configured to duplicate the second data, forward the duplicated second data to the first port, and output the second data. The first port is configured to transmit the duplicated second data to the first component and the second port is configured to transmit the duplicated first data to the second component. A data compression module is configured to compress the first and second data. Data storage is configured to store the compressed data.