Shield Board Power-over-EtherCAT Single Cable Design
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Solution Overview
Problem
Existing automation systems, particularly those using EtherCAT protocol, face challenges in efficient power distribution and compatibility due to the need for separate power cables and shared computational resources between base and shield boards, limiting their scalability and flexibility.
Innovation Solution
The implementation of a Power-over-EtherCAT system that uses a single Ethernet cable for both data communication and power supply, along with an EtherCAT shield that offloads computational tasks from the base board, enhancing compatibility and reducing the number of power cables required, and utilizing a generic data packet structure for universal communication protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate power cables and shared computational resources are used between base and shield boards, then compatibility is maintained, but device complexity and cable quantity increase
Solution Approach 1:
The patent combines power transmission and data communication functions into a single Ethernet cable connection. The shield board integrates both power reception and EtherCAT communication through one cable, eliminating the need for separate power cables and reducing overall system complexity while maintaining compatibility across different base boards.
Solution Approach 2:
The Ethernet cable is designed to serve multiple functions simultaneously: it transmits both power and data communication signals. The shield board's power module and communication module share the same physical connection interface, making the cable universal for both power supply and communication purposes.
2Reliability
If separate power cables are used for power distribution, then power supply reliability is ensured, but device complexity and installation complexity increase
Solution Approach 1:
Power supply and communication functions are merged into a single cable connection. The shield board receives both power and communication signals through the same Ethernet cable interface, simplifying installation by reducing the number of connections required while maintaining reliable power delivery through the integrated design.
3Device complexity
If shared computational resources are used between base and shield boards, then device complexity is reduced, but productivity and computational efficiency decrease
Solution Approach 1:
The patent extracts computational tasks from the base board and relocates them to the shield board's independent microcontroller. The shield board's power module and communication module operate autonomously with dedicated processing resources, eliminating the need to share computational resources with the base board while maintaining reduced overall system complexity.
Data Source
AI summary
An embodiment includes a system comprising: a first shield board that includes first and second connectors; wherein the first connector of the first shield board is configured to communicate with a first connector of a second shield board via a cable; wherein the first shield board has connectors configured to directly couple to connectors of a first base board; wherein the first shield board is configured to communicate data and power to the second shield board via the first connector of the first shield board, the cable, and the first connector of the second shield board. Other embodiments are addressed herein.