Slave Module Registration via Status Connectors in Modular Controllers
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Solution Overview
Problem
The manual configuration of network addresses for slave modules in modular controller systems is time-consuming, costly, and prone to human errors, while existing automated methods, such as daisy chaining, are less efficient in terms of costs and performance.
Innovation Solution
A slave module with a processing unit and a network adapter, featuring separate status input and output connectors, which automatically senses a trigger voltage to initiate a presentation message to the master module, facilitating automatic registration and network communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual configuration of network addresses is used for slave modules, then individual registration and network communication are achieved, but the process is time-consuming and costly
Solution Approach 1:
The slave module automatically determines its own position in the daisy chain by sensing voltage levels at its status input connector, and automatically registers itself with the master module without human intervention. This self-service mechanism eliminates manual configuration time while ensuring accurate individual registration.
Solution Approach 2:
The system performs preliminary voltage sensing and position determination before actual network registration. The slave module prepares its registration data and position information in advance based on voltage detection, enabling faster and more accurate registration when the process begins.
2Reliability
If manual configuration of network addresses is used for slave modules, then individual registration is achieved, but human errors occur
Solution Approach 1:
The slave module autonomously determines its position and configures its network address without human intervention. The automatic position determination based on voltage sensing eliminates human errors in manual configuration while maintaining configuration simplicity through a plug-and-play approach.
3Extent of automation
If daisy chaining is used for module connection, then automatic position determination is achieved, but network efficiency and performance are reduced
Solution Approach 1:
The system separates the position determination function (performed via voltage sensing on status connectors) from the network communication function (performed via the industrial network). This segmentation allows automatic position determination without forcing the entire network into a daisy chain topology, maintaining network efficiency while achieving automation.
Solution Approach 2:
The status input/output connectors with voltage sensing act as intermediaries between the physical connection and the network registration process. They provide automatic position determination information to the slave module without requiring the network itself to be organized in a daisy chain, thus preserving network communication efficiency.
4Extent of automation
If separate status input and output connectors are added to slave modules, then automatic registration is enabled, but device complexity increases
Solution Approach 1:
The status input and output connectors serve multiple functions: they provide position determination through voltage sensing, enable automatic triggering of registration for subsequent modules, and facilitate the enumeration process. This multi-functionality justifies the addition of connectors by providing comprehensive automation capabilities through a single integrated mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables cost-efficient and performant network commissioning by automating the registration process of slave modules, reducing human error, and improving overall system efficiency.
Implementation Method 1
The processing unit is capable of sensing a voltage applied at the status input connector with respect to an electric reference potential
Data Source
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AI summary
The present invention relates a slave module (1) for a modular controller system (100) including a master module (50) and employing an industrial network (90). The slave module (1) comprises a processing unit (10) and a network adapter (20) coupled to the processing unit (10). In order to facilitate the commissioning of the controller system (100) and to allow using a cost-efficient and performant network (90), the slave module (1) includes a separate status input connector (30) and a separate status output connector (40), each coupled to the processing unit (10). In an enumeration state, the slave module (1) sends, upon the processor unit (10) sensing that a trigger voltage is applied at the status input connector (30), a presentation message to a master module (50) via its network adapter (20) and the network (90). Further, it applies in the enumeration state, upon receiving a registration response from the master module (50) at the network adapter (20), a trigger voltage at the status output connector (40) by means of the processing unit (10). The present invention further relates to a controller system (100) and to a method for the iterative registration of slave modules (1) of a modular controller system (100).