Communication system comprising a controller system and a master control means connected via a multipole connection means

0001It is now commonplace in, for example, production machinery for all of the pneumatic or hydraulic equipment to be controlled by respective directional control valves that are usually mounted on one and the same 'valve island'. It will be appreciated that the term 'valve island' is intended to include devices such as 'valve manifolds' and the like. The valves in the valve islands are usually controlled by solenoids that receive electrical signals to cause them to actuate the associated valve. The valve islands are connected to a controller system, via a communication system, which sends the signals to control the operation of the valves on the valve island.

0002There are two main types of communication system in common usage; multipole and fieldbus. In a multipole communication system, each valve in the valve island has a separate communication line effectively connecting it directly to the controller system. Thus, a 25-pin or other common connector links the controller system and the valve island and each pin provides the control signal for a different valve on the valve island. Thus, the multipole system is easy to understand and use. However, as a separate line is required for each valve to be controlled a complex multipole-based system can be expensive with regard to the wiring requirements and the number of outputs at the controller system. Further, it can be confusing when attempting to identify faults.

0003The other type of communication system is an address-based fieldbus system. Here, the valve islands are connected together to form a network often using a two-wire medium. The controller system sends instructions that are addressed to a particular valve island and a control system on the island interprets the instructions and thus actuates the appropriate valve. Although the fieldbus control system provides more flexibility, it can appear complex due to the programming required to administer the system.

0004For example, <patcit id="pcit0001" dnum="DE19629868"><text>DE 19,629,868</text></patcit> discloses an arrangement for transmission of binary data in an interface system such as AS-i consisting of at least a transmission system, a slave module, and a master module. The transmission includes a two-wire cable used to exchange data between the master module and the slave module. The master module is connected to a higher-level control and communicates with addressed slave modules through a four-digit bit pattern.

0005<patcit id="pcit0002" dnum="DE3807149"><text>DE 38 07 149</text></patcit> discloses another arrangement utilizing self-addressed test package information. The self-addressed test package information is used in conjunction with a ring-shaped network to identify whether the addresses allocated to a specific subscriber device occur more than once in the ring-shaped network. Each subscriber device (TLN) transmits self-addressed address test packet information (ati). Because the subscriber devices are only capable of transmitting self-addressed test packages, <patcit id="pcit0003" dnum="DE3807149"><text>DE 38 07 149</text></patcit> provides the flexibility associated with addressed signals, but lacks the simplicity of programming offered by multipole connections.

0006<patcit id="pcit0004" dnum="JP7042865A"><text>JP 07-042865</text></patcit> discloses a solenoid valve control system wherein command parallel signals including information on the number of a receiving station and information on a drive command are sent to a communications control portion from a programmable controller, and are subjected to parallel-to-serial conversion to obtain serial signals including the information on the number of the station and the information on the command.

0007<patcit id="pcit0005" dnum="WO9404831A"><text>WO 94/04831</text></patcit> describes an electro-pneumatic control device which includes a valve station designed as a component assembly, the valve station including a fluid-distributor unit fitted with a multiplicity of valves and an electronic central control unit represented by a control block.

0008According to the present invention, a communication system as defined by independent claim 1 is provided.

0009This is advantageous as the system is easy to understand and set up, yet has the advantages of an addressable communication system such as the fieldbus system described above. In particular, the valves may be distributed over the "master" valve island and several "slave" valve islands (with the associated control means), and all of them can be controlled by the controller system via a single multipole connection means. Thus, the user can program the controller system as if the system is a multipole system, while the master control means interprets the instructions and can relay them to the appropriate slave valve island control means as required.

0010Preferably the controller system is a programmable logic controller (PLC).

0011The master and slave control means control fluid flow control valves. In particular, the master and slave control means are associated with valve islands and thus they control the solenoid operated valves thereon.

0012Preferably further slave control systems are connected to the communication system via addressable connection means in a chain-like manner.

0013The addressable connection means may be based on a Local Interconnect Network (LIN) standard. The LIN standard is a single wire communications standard between a master system and at least one slave system. Each slave system needs minimal configuration to operate which, when combined with the single wire medium, make it simple and cost efficient. Preferably, the addressable connection means is based on the Controller Area Network (CAN) standard. Most preferably, the addressable connection means is based on a RS485 standard. Thus, the master and slave control means may include transceiver means to enable them to communicate using the chosen protocol of the addressable connection means.

0014Preferably the multipole connection means comprises a 25-pin connector or a 44-pin connector. However, it will be appreciated that the multipole connector may be some other industrially accepted connector.

0015The master control means comprises a microprocessor. The slave control means may also comprise a microprocessor.

0016Preferably, the master control means includes a diode array that derives power for the master control means, and for the actuation of any devices that it controls, from the multipole input signal. Preferably, the slave control means derives power from the addressable connection means. The master control means preferably has signal conditioning means to ensure that the signals received from the multipole connection means are in a suitable form, and within a particular voltage range, for being received by the microprocessor of the control means.

0017Preferably the master and slave control means have output means for actuating the required valve. The output means may comprise an output array de-multiplexer. Alternatively, the output means may be adapted to use a serial signal from the control means to control the appropriate valve. This configuration of the output means forms the subject of the second aspect of the invention.

0018As the invention allows for various numbers of valves to be spread over a master valve island and several slave valve islands, for example, the system of the first aspect of the invention requires a flexible means of actuating specific valves. As the control means comprises a microprocessor it is advantageous if it can output a serial signal to actuate a valve on the valve island.

0019There now follows by way of example only a detailed description of the present invention with reference to the accompanying drawings in which; <ul id="ul0001" list-style="none"><li><figref idref="f0001"><b>Figure 1</b></figref> is a diagram showing the arrangement of the communication system of the invention;</li><li><figref idref="f0001"><b>Figure 2</b></figref> is a diagram of the master control means;</li><li><figref idref="f0002"><b>Figure 3</b></figref> is a diagram of the slave control means; and</li><li><figref idref="f0002"><b>Figure 4</b></figref> is a diagram of the output means.</li></ul>

0020A communication system 1 according to the invention is represented in <figref idref="f0001">Figure 1</figref>. The communication system 1 comprises a master control means 2 that receives control signals from a controller system (not shown) and a slave control means 3. The master control means 2 receives signals from the controller system via multipole connection means 4. The multipole connection means 4 shown in <figref idref="f0001">Figure 1</figref> uses a 25-pin D-type connector 5. The master control means 2 is in communication with each slave control means 3 via addressable connection means in the form of a sub-bus, which operates in accordance with the RS485 standard/protocol. The master control means 2 has a master sub-bus connector 6 for connecting it, via a sub-bus cable 7, to a slave sub-bus connector 8 on the slave control means 3. Thus, the master control means 2 forms the master node on a sub-bus (with the cable 7 forming part of the bus) and the slave control means 3 forms the slave node on the bus. The slave control system 3 has a further sub-bus connector 9 for connecting it to a further slave control means (not shown).

0021It will be appreciated that the addressable connection means may be based on a sub-bus that operates in accordance with other standards such as CAN or LIN depending upon the application of the system.

0022It will also be appreciated that additional slave control means may be added in a "chain-like" arrangement. The number of slave control means that may be added is limited by the electrical power that can be supplied via the multipole connection 4 or through subsequent connections, as it is the power received through the connection 4 that allows the subsequent control means to operate. However, the master or slave control means may be adapted to receive their own power supply.

0023The master control means 2 and the slave control means 3 are associated with valve islands (not shown). Thus, the control means 2, 3 control solenoid-actuated pneumatic valves mounted on the valve island. The pneumatic valves may be used to actuate production machinery or the like.

0024<figref idref="f0001">Figure 2</figref> shows a block diagram of the master control means 2, which is represented by the dashed lines. The diagram shows how the multipole signal 4 is used and how the signals are output to the sub-bus connector 6. The multipole signal 4 received by the control means 2 comprises twenty-five pins that provide the control signals 10 and a common 0 volts 11, which provides a ground for the system. The control signals 10 are received by signal conditioning means 12, which prepares the signals 10 for being received by a microprocessor 15. In particular, the signal conditioning means 12 reduces the voltage of the signals from typically 24 volts to a voltage that can be reliably interpreted by the microprocessor 15.

0025The signal conditioning means outputs a signal 13 that is received by the microprocessor 15. The microprocessor 15 interprets the signal and determines whether the valve to be actuated (not shown) is located on the valve island with which the control means 2 is associated or with which the slave control means 3 is associated. If it is determined that the valve to be actuated is controlled by the slave control means 3, the microprocessor 15 prepares the appropriate addressed signal for transmission on the sub-bus 7 of the addressable connection means. The output signal 16 is a serial signal to a sub-bus transceiver 17.

0026The sub-bus transceiver 17 modifies the signal 16 in accordance with the protocol/standard of the sub-bus (RS485) and then outputs the addressed data signal for transit over the sub-bus at 26. The output 26 is connected to the sub-bus connector 6 for transmitting along the sub-bus cable 7.

0027The control signals 10 split as they enter the control means 2 and as well as being received by the signal conditioning means 12, they are received by a diode array 18. The control signals 10 are used to provide power for the components 15, 17 of the master control means 2 and for transmission to the further slave control means 3, via the sub-bus cable 7. The outputs 14 are received by a diode array 18. The diode array 18 combines the control signals 10 in the nature of an OR-gate to a single 24 volt power output 19. The 24 volts output 19 branches into a first line 20 and a second line 21. The first line 20 connects to the sub-bus connector 6 to provide power for the subsequent slave control means 3. The second line 21 is received by a voltage regulator 22 that regulates the 24 volt input 21 to a voltage suitable for operating the logic of the microprocessor 15 and the sub-bus transceiver 17. Thus, the voltage regulator 22 has an output 23 that branches into separate lines 24, 25 to supply power to the microprocessor and sub-bus transceiver respectively.

0028The outputs from the master control means 2 are output via the sub-bus connector 6. Thus, there are three separate signals that are passed along cable 7; the 24 volt output 20 from the diode array 18, a common 0 volt output 27 derived from the input 11 and the data signal 26. Although only one pin is shown for the data signal 26, there will be as many pins as required by the communication standard used for the addressable connection means.

0029A diagram of the slave control means 3 is shown in <figref idref="f0002">Figure 3</figref>. The slave control means 3 receives the three signals 20, 26 and 27 via the cable 7 and connector 8. The data signal 26 is received by a sub-bus transceiver 28, which interprets the signal in accordance with the RS485 standard/protocol. The sub-bus transceiver 28 outputs the signal at 29, which is received by a microprocessor 30. The microprocessor interprets the signal and if required passes instructions 31 to output means 32. Thus, the microprocessor interprets the serial data signal 29 from the sub-bus transceiver 28 and, if required, outputs a signal 33 via the output array 32. The output 33 from the output means 32 controls the appropriate solenoid valve on the valve island with which the control means 3 is associated.

0030The 24 volts input 20 splits when it enters the slave control means 3, one line being received by a voltage regulator 34 and the other by the output means 32. The output means uses the 24 volts to actuate the solenoids on the valve island (not shown). The voltage regulator 34, as in the master control means 2, has outputs 35 and 36 to provide power for the sub-bus transceiver 28 and the microprocessor 30, respectively.

0031The microprocessor 30 of the slave control means 3 has two-way communication with the sub-bus transceiver 28 and thus further slave control means can be attached to data line 26 (the sub-bus) via the second sub-bus connector 9 (shown in <figref idref="f0001">Figure 1</figref>). The second sub-bus connector 9 is connected to the sub-bus transceiver 28.

0032In use, the controller system (not shown) passes a multipole signal 4 to the master control means 2 to actuate a specific valve on either of the valve islands associated with control means 2, 3. The signal conditioner 12 receives the multipole control signals 10 and outputs the conditioned signals 13. The microprocessor 15 of the master control means 2 receives power from the voltage regulator 22 and receives the signals 13. The microprocessor 15 then, in accordance with its program, determines whether the valve to be actuated is located on the valve island with which it is associated. If so, it passes the appropriate signal to output means (not shown). If the valve is determined to be associated with the slave control means 3, the microprocessor prepares an addressed signal 16 and passes it to the sub-bus transceiver 17. The sub-bus transceiver 17 transmits it along the sub-bus cable 7 to the slave control means 3 in accordance with the protocol of the sub-bus. The signal is received by the sub-bus transceiver 28 of the slave control means 3. The transceiver 28 interprets and then outputs signal 29 to the microprocessor 30 of the slave control means 3. The microprocessor 30 processes the signal 29 in accordance with its program to determine if the signal is addressed to it and thus if a valve connected to the slave control means 3 should be actuated. If so, the appropriate signal 31 is sent to the output means 32, which causes the appropriate valve to be actuated. If the microprocessor determines that the signal 29 is not addressed to it, it is ignored.

0033The signal 26 is also relayed to any subsequent slave control means 3 by the sub-bus transceiver 28, via the further sub-bus connector 9, and any further slaves (not shown) processes the signal as described above.

0034The microprocessors 15, 30 may be pre-programmed or the user, via a RS232 interface or Bluetooth, may set the program, for example. Thus, the user may be able to program which valve or combination of valves are actuated in response to each multipole input 10.

0035Thus, many valve islands can be controlled from a single 25-pin (or other standard connector) multipole based system. In practice, it is common for a single valve island not to include a complete quota of valves thereon and therefore not all of the pins would be in use. Thus, with a standard multipole system a user may require several valve islands each connected by separate multipole connectors. The present invention allows the valves to be spread over a master and several slave valve islands that are controlled via the master control means. This reduces the amount of cabling required and the number of outputs at the controller system. Therefore, the system of the invention has the simplicity and ease of use of a multipole system, while having the flexibility of a Fieldbus system.

0036An output means 40 (as shown in <figref idref="f0002">Figure 4</figref>) comprises actuation signal arrangement means 41, 41' and actuation means 42, 42'. Each pair 43, 44 of actuation signal arrangement means 41, 41' and actuation means 42, 42' are associated with a fluid flow control means in the form of a solenoid operated valve (not shown). The actuation signal arrangement means 41, 41' comprise a "D" type flip-flop having a power supply line 45, an edge-triggered clock signal input 46, a pre-actuation signal data input 47, 48, a pre-actuation signal data output 49, 50 and a 0 volts line 51. The data outputs 49, 50 branch to connect to the associated actuation means 42, 42'.

0037The actuation means 42, 42' comprise a "D" type latch. Inputs 52 and 53 to the latches 42, 42' are from outputs 49 and 50 respectively. The latches 42, 42' also have a power supply line 45 and 0 volts line 51. The latches 42 and 42' are connected to the valves by output lines 54 and 55. The latches 42, 42' also have inputs 56 for receiving an actuation signal. Thus, the output means 40 is of the form of a 2-bit serial latch.

0038The clock signal input 46, the pre-actuation signal data input 47 and the edge-triggered actuation signal input 56 are all received from the master or slave microprocessor 15, 30. The above inputs are digital and thus take the form of either a "1" or a "0".

0039In use, the sequence in which the above signals are applied determines which valves are actuated. For example, to actuate the second valve in the chain a pre-actuation signal of "1" is applied to the input 47 at the same time as a clock pulse at input 46. As will be appreciated, this causes the pre-actuation signal of "1" to appear at output 49 and therefore form the input of the second flip-flop 41' at input 48. During the second clock cycle, the pre-actuation signal is "0". Thus, after the second clock pulse at input 46, there is a pre-actuation signal of "0" at output 49 and the pre-actuation signal of "1" now appears at output 50.

0040The microprocessor 15, 30 now outputs an actuation signal to input 56. As the outputs 49 and 50 form the inputs 52 and 53, after the actuation signal, a "0" will appear at valve output 54 and a "1" will appear at valve output 55. Thus, the first valve in the chain will not be actuated, as it will receive a "0" signal, while the second valve in the chain will be actuated, as it receives the pre-actuation signal of "1".

0041If another valve is added, the pre-actuation signal data input of the additional flip-flop/latch pair can be connected to the output 50. Further valves can be added in a similar manner. Thus, it will be appreciated that this method can be used to actuate any valve in the chain of valves or any combination thereof, as the pre-actuation signals are fed into the chain at input 47 and then "passed through" the flip-flops by the clock signal edge. Once the clock signal has cycled the required number of times and the pre-actuation signals form the input of the appropriate latch 42, 42', the actuation signal is applied to pass the signals to the appropriate valve.

0042This method may also be used in a configuration mode to allow the microprocessor to determine how many valves are connected to the valve island with which it is associated. At the end of the chain of flip-flop/latch pairs 43, 44 the output 50 returns to the microprocessor. Using the example as shown in <figref idref="f0002">Figure 4</figref>, during a configuration mode a pre-actuation signal of "1" is applied at input 47 during the first clock cycle at input 46. After the first clock cycle the pre-actuation signal is kept as "0". The microprocessor 15, 30 then counts the number of clock cycles applied at inputs 46 until the pre-actuation signal of "1" returns to it. The number of valves can thus be determined by counting the number of clock pulses applied during this configuration mode.

0043Further, during the configuration mode the microprocessor 30 of each slave control means 3 may pass the information of the number of valves associated with it back to the master control means 2. Thus, the master control means can then determine which valve is attached to which slave control means 3 and therefore address the appropriate one in response to the multipole signals 10.