Wireless Backplane Extender for Distributed I/O Systems
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Solution Overview
Problem
Existing modular distributed I/O systems in industrial automation face challenges such as insufficient slots, large physical size, high costs, limited cable extension distances, signal degradation, and environmental issues with conventional cable-based backplane extensions.
Innovation Solution
A wireless backplane extender system using a primary wireless device connected to an industrial controller and secondary wireless devices, establishing a radio frequency link for seamless data transfer between I/O modules, eliminating the need for physical cables and allowing greater flexibility and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If cables are used to extend the backplane, then the I/O system can be physically extended to remote locations, but the cost increases and the physical size becomes large
Solution Approach 1:
The patent replaces the mechanical cable-based backplane extension system with a wireless communication system. The wireless backplane extender uses radio frequency communication to transmit data between I/O modules, eliminating the need for physical cables and reducing the overall physical size of the system while maintaining extended reach.
Solution Approach 2:
The patent extracts the cable connection requirement from the backplane extension system. By removing the cable-based mechanical connection and replacing it with wireless communication, the system achieves physical extension without the bulk and complexity of cable infrastructure.
2Length of stationary object
If cables are used to extend the backplane, then remote I/O modules can communicate with the controller, but signal degradation occurs over distance
Solution Approach 1:
The patent replaces the cable-based electrical signal transmission system with a wireless radio frequency communication system. This substitution eliminates signal degradation issues associated with long cable runs while maintaining reliable data communication over extended distances through wireless backplane extender technology.
3Length of stationary object
If cables are used for backplane extension, then I/O modules can be connected remotely, but cable-to-backplane interfaces create environmental contamination risks
Solution Approach 1:
The patent removes the cable-to-backplane interface from the system entirely by implementing wireless communication. This extraction eliminates the interface points that are vulnerable to environmental contamination, while still allowing remote mounting locations to be connected through wireless backplane extender technology.
4Device complexity
If a finite number of slots are provided on the backplane, then the system structure is simplified, but the number of I/O modules that can be connected is limited
Solution Approach 1:
The patent replaces the fixed-slot mechanical backplane structure with a wireless communication-based modular system. This allows I/O modules to be connected without physical slots, enabling unlimited numbers of modules to be added to the system while maintaining simplified wireless communication architecture.
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
The wireless backplane extender system provides a cost-effective, flexible, and reliable solution for extending I/O systems, reducing physical constraints and environmental risks, while maintaining data integrity and enabling communication over longer distances.
Implementation Method 1
A secondary wireless device is operatively connected to the primary wireless device by a primary wireless backplane link
Data Source
AI summary
A distributed modular input/output system includes a primary wireless device adapted to be operatively connected to an associated industrial controller. A secondary wireless device is physically disconnected from the primary wireless device. The secondary wireless device is operatively connected to the primary wireless device by a primary wireless backplane link. At least one input/output module is operatively connected the secondary wireless device. An associated field device can be connected to the at least one input/output module for communication with the associated industrial controller via the secondary wireless device, the primary wireless backplane link, and the primary wireless device. Typically, a plurality of the secondary wireless devices are physically disconnected from the primary wireless device and each includes one or more of the input/output modules operably connected thereto. Each of the secondary wireless devices is operatively connected to the primary wireless device by a respective plurality of primary wireless backplane links.