Radio Aggregating Sensor Data for Slave Control
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Solution Overview
Problem
In factory automation, wireless communication for sensor data collection is hindered by noise and lack of studies on configuration, leading to instability and constraints in arranging control devices, while conventional wired connections are preferred due to reliability concerns.
Innovation Solution
A radio system that enables wireless communication with sensors and connects to a slave control apparatus via a single cable, allowing data transmission through wired communication, with a generation unit forming communication packets that include sensor data in a predetermined order for identification and transmission to the master control apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wireless communication is used for sensor data collection, then arrangement flexibility and elimination of cables are improved, but reliability deteriorates due to noise in the factory environment
Solution Approach 1:
The patent combines wireless communication capabilities into a single radio device that aggregates data from multiple sensors, then transmits the consolidated data through a single wired connection to the slave control apparatus. This merging approach preserves arrangement flexibility for sensor placement while ensuring reliable data transmission through the wired backup connection.
Solution Approach 2:
The radio device acts as an intermediary between the sensors and the slave control apparatus. It collects data wirelessly from multiple sensors, processes and packages the data, then transmits it reliably through a wired connection to the control system, thereby mediating between the flexible wireless sensing layer and the reliable wired control layer.
2Reliability
If multiple wired connections are made between radio and control apparatus, then communication reliability is improved, but device complexity and cable management deteriorate
Solution Approach 1:
The patent merges multiple communication functions into a single wired connection between the radio and the slave control apparatus. The radio aggregates data from multiple sensors and transmits all information through one communication port, eliminating the need for multiple separate cable connections while maintaining reliable communication.
Solution Approach 2:
The single wired connection between the radio and slave control apparatus serves multiple functions: it transmits sensor data, maintains synchronization information, and provides a reliable communication channel. This multi-functional approach reduces cable complexity while ensuring comprehensive communication reliability.
3Ease of manufacture
If wireless communication is adopted in FA systems, then ease of installation and cable elimination are improved, but system stability deteriorates due to lack of regulatory stability
Solution Approach 1:
The patent segments the communication system into two distinct layers: a wireless sensing layer for flexible sensor data collection and a wired control layer for stable data transmission to the master control apparatus. This segmentation allows each layer to optimize for its specific function while contributing to overall system stability.
Solution Approach 2:
The radio device serves as a stable intermediary that bridges the wireless sensor network and the wired control system. It ensures regulatory stability by maintaining a reliable wired connection to the slave control apparatus while enabling flexible wireless sensor placement, thereby combining ease of installation with system stability.
Data Source
AI summary
Provided is a radio formed to be capable of performing wireless communication with sensors, and configured to be connected, through one communication port via wired communication, to a slave control apparatus configured to be communicably connected to a master control apparatus with a predetermined communication method. The radio generates one communication packet formed with the predetermined communication method and transmitted from the radio to the slave control apparatus, such that pieces of measured data measured by the sensors are included in the one communication packet in accordance with a predetermined order in which the slave control apparatus or the master control apparatus can determine which sensor measured which piece of the measured data of the sensors, and the radio transmits the generated one communication packet to the slave control apparatus via wired communication.