Stackable Distributed Control Hub With Offset Stacking For Port Inspection
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Solution Overview
Problem
Existing manufacturing facilities face challenges in integrating diverse actuators and sensors with different communication protocols, requiring manual data input and separate control systems, which complicates factory management and production processes.
Innovation Solution
A stackable distributed communication and control hub (DCCH) with offset brackets for wide viewing angles, dynamically reconfigurable connection ports, and in-line signal processing devices that automatically identify and convert between various communication protocols, allowing seamless integration of edge devices with different communication protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate control systems are used for different actuators and sensors with different communication protocols, then each device can be controlled independently, but the overall system complexity increases and manual data input is required
Solution Approach 1:
The patent implements a universal control system capable of supporting multiple communication protocols (Modbus, Profibus, EtherNet/IP, IO-Link) within a single platform. The system uses configurable communication modules that can be dynamically assigned to different protocols, eliminating the need for multiple separate control systems while maintaining compatibility with diverse actuators and sensors.
Solution Approach 2:
The patent introduces a protocol conversion module that acts as an intermediary between devices using different communication protocols. This mediator translates messages between protocols, enabling seamless communication between actuators and sensors using different protocol standards without requiring separate control systems for each protocol type.
2Loss of information
If manual data input is used to collect data from various systems, then data can be analyzed and managed, but time and labor costs increase
Solution Approach 1:
The patent implements automated data collection functionality where the control system automatically retrieves data from connected actuators and sensors through supported communication protocols. The system performs self-configuration and data aggregation without requiring manual data input, thereby eliminating time and labor costs associated with manual data collection while maintaining comprehensive data management capabilities.
3Ease of operation
If connection ports are stacked without offset, then the structure is compact, but the viewing angle for inspecting connections is limited
Solution Approach 1:
The patent introduces an offset configuration in the stacking arrangement of communication hubs. Instead of aligning connection ports vertically, the hubs are positioned with a horizontal offset, creating an asymmetric arrangement that spreads connection ports across different spatial planes. This asymmetric stacking provides improved viewing angles for connection inspection while maintaining a compact overall structure.
4Adaptability or versatility
If legacy equipment is integrated into modern control systems, then system consolidation is achieved, but communication protocol compatibility challenges arise
Solution Approach 1:
The patent implements protocol conversion modules that serve as intermediaries between legacy equipment and modern control systems. These modules translate communication protocols, enabling legacy devices to communicate with contemporary control architectures without requiring complete system replacement. The intermediary handles protocol translation transparently, simplifying integration while managing complexity internally.
Data Source
AI summary
Apparatus and associated methods relate to a stackable distributed communication and control hub (DCCH) configured to provide a wide viewing angle for instantly inspecting multiple connections when multiple DCCHs are stacked. In an illustrative example, a DCCH may include multiple connection ports distributed on one or more edge surfaces. An offset bracket, for example, may couple two DCCHs, each at a coupling surface of the corresponding DCCH. Upon coupling, the DCCHs are held at substantially parallel planes. For example, a first DCCH is offset from a second DCCH in two directions. In a first direction, respective planes are offset along a vertical axis by a predetermined first offset. In a second direction, the DCCHs are offset by a predetermined second offset, orthogonal to the first direction. Various embodiments may advantageously allow visual status of the connection ports visible in at least one viewing angle along the vertical axis.