Wireless Radio Bridge for Existing Wired FA Control Networks
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Solution Overview
Problem
In the factory automation (FA) field, there is a challenge in using wireless communication for control and data collection due to noise interference and the lack of established configurations for wireless driving of apparatuses, making it difficult to introduce radios into systems with master and slave control apparatuses while maintaining regulatory stability.
Innovation Solution
A radio is connected to a slave control apparatus via a cable, enabling wireless communication with driving apparatuses, and a transfer control unit mediates data transfer, creating a virtual connection that allows the radio to function as if the driving apparatuses are directly connected to the slave control apparatus, maintaining conventional communication methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If wireless communication is used for data transfer between sensors and control apparatuses, then the area coverage and flexibility of sensor deployment is improved, but the reliability of signal transmission deteriorates due to noise interference in factory environments
Solution Approach 1:
A radio device is introduced as an intermediary component between the wired control apparatus and wireless sensors/driving apparatus. The radio connects to the control apparatus via wired connection and communicates with sensors/driving apparatus wirelessly, serving as a mediator that leverages both wired reliability and wireless flexibility to resolve the contradiction between area coverage and signal transmission reliability
Solution Approach 2:
The system is segmented into three distinct functional components: the master control apparatus (wired), the radio device (hybrid), and the sensors/driving apparatus (wireless). This segmentation allows each component to operate in its optimal communication mode while maintaining overall system reliability through the radio's mediation
2Ease of manufacture
If wireless communication is introduced into existing FA systems, then the ease of installation and system flexibility is improved, but the complexity of system configuration and integration increases
Solution Approach 1:
The radio device automatically performs identification information collection and data transfer mediation without requiring complex manual configuration. The system enables itself to adapt to wireless communication by automatically managing the integration between wired and wireless components, reducing configuration complexity while maintaining ease of installation
Solution Approach 2:
The radio device is designed with multi-functionality, serving as both a wired communication interface and a wireless communication hub. This universal design allows the same device to handle both wired connections to the control apparatus and wireless connections to sensors/driving apparatus, simplifying system configuration while providing installation flexibility
3Adaptability or versatility
If wireless communication is used for controlling driving apparatuses, then the adaptability of control systems is improved, but the regulatory stability required in FA applications deteriorates
Solution Approach 1:
The radio acts as a stable intermediary that maintains regulatory stability through its wired connection to the control apparatus while enabling adaptive wireless control of driving apparatuses. This dual-connection approach preserves the stability required in FA applications while introducing the adaptability of wireless communication
Data Source
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AI summary
Provided is a radio formed to be capable of performing wireless communication with one driving apparatus, and configured to be connected, through one communication port via wired communication, to a slave control apparatus configured to be communicably connected to a master control apparatus with a predetermined communication method, the radio including an identification information collection unit collecting, from the one driving apparatus, identification information for identifying the one driving apparatus, when the radio is initially connected to the one driving apparatus via wireless communication, and a transfer control unit mediating data transfer between the master control apparatus and the one driving apparatus, such that the one driving apparatus is directly connected to the one communication port in a virtual manner, based on the identification information of the one driving apparatus collected by the identification information collection unit. Accordingly, it is possible to easily introduce the radio into a system constituted by a master control apparatus and a slave control apparatus in the FA field.