Numerical Controller I/O Signal Transfer Grouping
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Solution Overview
Problem
In master-slave communication between a numerical controller and I/O units, slaves farther from the master experience longer reply times and more frequent communication leads to longer waiting times and bandwidth waste due to the trade-off between transfer period and the number of signals.
Innovation Solution
A numerical controller is configured with a timer circuit, counter unit, and I/O unit transfer order setting unit to manage DI/DO signal transfers by grouping I/O units based on distance from the controller, allowing for varying transfer periods to optimize signal transfer timing and reduce idle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If signals are transferred to all I/O units in a fixed-period, time-sharing manner, then the transfer period can be fixed, but the responsiveness is reduced when the number of signals increases
Solution Approach 1:
The patent segments the I/O units into multiple groups based on their distance from the master and communication requirements. Each group is assigned a different transfer period, allowing near slaves to communicate more frequently than far slaves. This segmentation resolves the contradiction by enabling fixed periodic transfers within each group while improving overall responsiveness without increasing total bandwidth consumption.
Solution Approach 2:
The patent implements dynamic transfer periods for different I/O unit groups rather than a uniform fixed period. The transfer period is adjusted dynamically based on the slave's position in the chain and its communication needs, allowing the system to adapt the communication frequency to actual requirements and reduce unnecessary waiting times.
2Quantity of substance
If the transfer period is extended to increase the number of signals, then more signals can be transferred, but the responsiveness is inevitably reduced
Solution Approach 1:
By segmenting I/O units into groups with different transfer periods, the patent allows multiple signal groups to be transferred simultaneously at different rates. Near slaves with shorter transfer periods can be updated frequently, while far slaves use longer periods, enabling the system to handle more total signals without sacrificing responsiveness for critical near slaves.
Solution Approach 2:
Different parts of the I/O unit chain receive different transfer period allocations based on their local requirements. Slaves closer to the master receive shorter transfer periods for higher responsiveness, while slaves farther away use longer periods. This local quality differentiation allows the system to optimize responsiveness where needed while managing overall signal capacity.
3Reliability
If more frequent communication is performed with slaves farther from the master, then data updating improves, but waiting times for replies increase and bandwidth is wasted
Solution Approach 1:
The patent applies different transfer period qualities to different locations in the slave chain. Slaves farther from the master are assigned longer transfer periods appropriate to their distance and communication capabilities, rather than forcing uniform frequent communication. This local quality adjustment maintains data updating reliability for each slave's specific context while minimizing overall waiting times and bandwidth waste.
Solution Approach 2:
The system dynamically assigns transfer periods based on slave position and requirements rather than using a static uniform period. This dynamic allocation ensures that each slave receives appropriate communication frequency for its location, improving data updating where needed while avoiding excessive communication that would waste bandwidth and increase waiting times for other slaves.
Data Source
AI summary
A numerical controller is chain-connected with a plurality of I/O units so that it transmits DI/DO signals to and receives DI/DO signals from the I/O units by master-slave communication. The numerical controller counts signals generated by a timer circuit up to a predetermined number and sets, from among the plurality of I/O units, an I/O unit with which transfer of the DI/DO signals is to be performed for each count value. The DI/DO signals of the set I/O units are transferred according to the count value.