Wireless Tool Controller Protocol Switching
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Solution Overview
Problem
Current communication systems for industrial tools and controllers are manual, prone to human error, require additional hardware connections, and are difficult to maintain, especially when wireless connectivity is not available, limiting their use in industrial settings where precision and convenience are crucial.
Innovation Solution
A method for establishing wireless communication between tools and controllers using an initial pairing protocol, followed by a switch to a new protocol for ongoing communication, allowing for automated configuration and data exchange without the need for PC applications or physical connections, enabling point-to-point communication and reducing the complexity of setting up and maintaining connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cabled connection is used between the controller and the tool, then communication reliability is improved, but the ease of operation deteriorates due to the need for physical connection and certified electricians
Solution Approach 1:
The patent replaces the mechanical cable connection system with a wireless communication system. The controller and tool establish communication through wireless signals (e.g., Wi-Fi, Bluetooth, or other wireless protocols), eliminating the need for physical cable connections. This substitution maintains communication reliability while dramatically improving ease of operation, as users can pair and communicate without physically connecting cables or requiring certified electricians.
2Ease of operation
If a PC application is used for pairing and configuration, then communication setup is achieved, but the device complexity increases due to additional hardware and software requirements
Solution Approach 1:
The patent extracts and removes the PC application component from the communication setup process. The pairing and configuration functions are now built directly into the controller and tool devices themselves, allowing users to perform all setup operations directly on the devices without requiring an external PC or third-party software. This reduces system complexity by eliminating unnecessary hardware and software layers.
Solution Approach 2:
The controller and tool are designed to perform pairing and configuration operations autonomously without external assistance. The devices can automatically discover each other, establish connections, and exchange configuration data through their own integrated wireless communication capabilities, eliminating the need for PC-based configuration tools and reducing overall system complexity.
3Reliability
If manual pairing process is used, then communication connection is established, but the productivity decreases due to time-consuming setup and potential human error
Solution Approach 1:
The patent implements preliminary action by pre-configuring the controller and tool with unique identifiers, authentication credentials, and communication parameters before the actual pairing process. When pairing is initiated, these pre-configured elements enable automatic recognition and connection establishment, significantly reducing setup time and eliminating manual configuration steps that are prone to human error.
Solution Approach 2:
The patent incorporates feedback mechanisms where the controller and tool automatically exchange status information, connection confirmation, and configuration data during the pairing process. This automated feedback loop ensures accurate connection establishment while reducing setup time, as the devices can immediately verify and confirm pairing success without requiring manual verification steps.
Data Source
AI summary
A communication method is provided for communicating data between a tool and a controller. The method includes establishing communication between the tool and the controller using a first wireless communication protocol. Once wireless communication has been established, the tool and the controller switch to a new wireless communication protocol that is different from the first protocol. Operational settings are then wirelessly communicated by the controller to the tool using the second protocol.