Y Selector Switch for IO-Link Sensors on Analog Controllers
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Solution Overview
Problem
In automation and process engineering, intelligent IO-Link capable sensors are often connected to non-intelligent controllers that only support analog and/or switching signal inputs, resulting in unused additional data due to the lack of direct digital communication capabilities, especially in the Industry 4.0 context where accessing sensor data without changing the communication system is necessary.
Innovation Solution
A Y selector switch unit is introduced, dividing the communication line into two partial lines, with a further data receiver connected to one line to extract and process digital IO-Link data from the sensor, allowing binary switching signals to be forwarded unaltered to the controller, enabling access to digital communication data without affecting the sensor-controller interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If an IO-Link capable sensor is connected to a non-intelligent controller, then the sensor can provide digital data, but the controller cannot process it and the data remains unused
Solution Approach 1:
The patent introduces a Y-selector switch unit as an intermediary device between the IO-Link sensor and the non-intelligent controller. This mediator extracts binary switching signals from the digital IO-Link communication and forwards them to the controller's analog/switching input, enabling the controller to utilize sensor data without requiring digital communication capabilities. The Y-selector switch unit thus bridges the communication protocol gap between intelligent sensor and non-intelligent controller.
2Adaptability or versatility
If the communication line is divided into two partial lines with a Y selector switch unit, then digital data can be accessed by a further data receiver, but the controller interface may be affected
Solution Approach 1:
The patent segments the communication line into two separate partial lines using the Y-selector switch unit. One line maintains the original IO-Link connection between sensor and further data receiver, while the other line provides extracted binary signals to the controller. This segmentation allows independent operation of both data access paths, enabling versatile data access without interfering with the established sensor-controller interface reliability.
3Ease of operation
If a further data receiver is connected to access digital IO-Link data, then sensor data becomes available for monitoring, but the original sensor-controller connection must be modified
Solution Approach 1:
The Y-selector switch unit performs multiple functions simultaneously: it maintains the IO-Link communication path for further data receivers, extracts binary switching signals for the non-intelligent controller, and provides a universal interface that accommodates both digital and analog/switching communication protocols. This multi-functionality enables easy data monitoring without requiring separate modification of the original sensor-controller connection.
Data Source
AI summary
The disclosure relates to a communication system for automation and process engineering, having a controller as a signal receiver and a sensor as a signal source, which interchange voltage and/or current signals via a connection line, wherein the sensor is suitable for providing digital data according to the IO-Link standard, and the controller has only an analogue and/or switching signal input. In order to make it possible for the user to be able to easily access the data from an IO-Link-enabled sensor in the communication system if the control unit itself is not suitable for this purpose, the communication line is divided into two partial lines and a Y selector switch unit is used at the connection point, wherein a first connection is provided on the sensor side and a second and a third connection are provided on the controller side on the Y selector switch unit, wherein the controller is connected to the second connection and a further data receiver is connected to the third connection, and wherein the Y selector switch unit provides the further data receiver with the digital data according to the IO-Link standard from the sensor at the third connection and comprises an evaluation and processing unit which taps off the digital data according to the IO-Link standard from the sensor, extracts a binary switching signal therefrom and provides the controller with said signal at the second connection, with the result that the further data receiver can query the digital data from the sensor and can access the sensor without the signals between the sensor and the controller being influenced thereby.