System and method for motor control center trunk and tap connectors

Abstract

A system includes a multi-tap cable and a connector. The connector is configured to be coupled to one or more MCC detachable units installed in one or more respective bins of an MCC, wherein the connector is configured to couple and decouple the one or more MCC detachable units to the multi-tap cable without interrupting a network or a subnet of the MCC.

Description

Technical Field

[0001] This disclosure generally relates to motor control centers (MCCs) for industrial automation systems. More specifically, this disclosure relates to MCCs for connecting detachable MCC units to industrial automation systems, as well as trunking and tap connectors for disconnecting detachable MCC units from the MCCs of industrial automation systems. Background Technology

[0002] Industrial automation systems can be used to provide automated control of one or more actuators. A controller can output a regulated power signal to the actuator to control its movement. Multiple controllers of an industrial automation system can be combined with other components and housed in a housing to form an MCC (Multi-Channel Control Unit). The MCC is divided into vertical sections, each of which is further divided into one or more buckets. The buckets are configured to receive units (e.g., industrial automation equipment parts). The various components and / or units of the MCC, as well as the components within these units, can communicate with each other via a wired network or subnet. For example, multi-tap cables can pass through the housing of the MCC and communicatively couple to the units and / or components within the MCC. If a unit of the MCC is inserted or removed for an excessively long period, the insertion or removal of the unit may interfere with the network and / or subnet. Therefore, a method is needed to insert and remove units from the MCC without interfering with the network and / or subnet. Summary of the Invention

[0003] In one embodiment, a system includes a multi-tap cable and connectors. The multi-tap cable includes a first connector and a second connector. The first connector includes a first terminal configured to communicatively couple to a first unit in a first bucket of a motor control center (MCC) in an industrial automation system. The second connector is configured to couple to a second unit in a second bucket of the MCC, wherein the second unit includes a detachable MCC unit, and wherein the second connector is configured to couple the detachable MCC unit to the multi-tap cable without interrupting the network or subnet of the MCC, and to decouple the detachable MCC unit from the multi-tap cable.

[0004] In another embodiment, a first connector is configured to communicatively couple the trunk of a multi-tap cable to a detachable motor control center (MCC) unit of an MCC used in an industrial automation system. The trunk of the multi-tap cable is communicatively coupled to a second connector including first terminals. The first connector includes: one or more input pins communicatively coupled to one or more conductors extending through the trunk of the multi-tap cable; and one or more output pins communicatively coupled to one or more conductors extending through the trunk of the multi-tap cable. The first connector connects multiple nodes associated with the detachable MCC unit mounted in a bucket within the MCC to a network or subnet of the MCC.

[0005] In another embodiment, a system includes a motor control center (MCC) of an industrial automation system and a multi-tap cable. The MCC includes a first drum and a second drum. The multi-tap cable includes: a first connector coupled to a first end of a main line and having a first terminal configured to communicatively couple to a first unit mounted in the first drum of the MCC; and a second connector coupled to a second end of the main line. The second connector is configured to communicatively couple to a second unit mounted in the second drum of the MCC, wherein the second unit includes a detachable MCC unit. The second connector is configured to couple the detachable MCC unit to the multi-tap cable without interrupting the network or subnet of the MCC, and to decouple the detachable MCC unit from the multi-tap cable. Attached Figure Description

[0006] These and other features, aspects, and advantages of this embodiment will become better understood when the following detailed description is read with reference to the accompanying drawings, in which the same reference numerals denote the same parts throughout the drawings:

[0007] Figure 1 This is a schematic diagram of an industrial automation system based on the embodiments presented in this document;

[0008] Figure 2 This is a front view of an embodiment of the MCC according to the embodiments presented herein;

[0009] Figure 3 Based on the embodiments presented herein Figure 2 A perspective view of a portion of the multi-tap cable used in the MCC;

[0010] Figure 4 It is based on the implementation method presented in this document. Figure 3 A cross-sectional view of a portion of the multi-tap cable shown;

[0011] Figure 5A This is a schematic diagram of the trunk and tap connectors according to the embodiments presented herein, wherein the node unit is from... Figure 3 and Figure 4 The main branch of the multi-tap cable shown is disconnected;

[0012] Figure 5B It is based on the implementation method presented in this document. Figure 5A A schematic diagram of the trunk line and tap connectors, wherein the node unit is connected to the trunk line of the multi-tap cable;

[0013] Figure 6A It is based on the implementation method presented in this document. Figure 5A and Figure 5B A schematic diagram illustrating the implementation of the trunk line and tap connectors;

[0014] Figure 6B It is based on the implementation method presented in this document. Figure 5A and Figure 5B A schematic diagram illustrating the implementation of the trunk line and tap connectors;

[0015] Figure 7 This is a schematic diagram of an MCC according to the embodiment presented herein, wherein one of the barrels is connected to a multi-tap cable via a trunk line and tap connectors;

[0016] Figure 8 This is a schematic diagram of an MCC having two drums connected to a multi-tap cable via a trunk line and tap connectors, according to the embodiment presented herein; and

[0017] Figure 9 This is a flowchart of process 700 for connecting a detachable MCC unit to the trunk and tap connectors of a multi-tap cable. Detailed Implementation

[0018] One or more specific implementations will be described below. To provide a concise description of these implementations, not all features of the actual implementations are described in this specification. It should be understood that in the development of any such implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related constraints and business-related constraints, which may vary depending on the implementation. Furthermore, it should be understood that such development efforts may be complex and time-consuming, but will remain routine tasks of design, manufacturing, and production for those skilled in the art who benefit from this disclosure.

[0019] In describing the elements of various embodiments of this disclosure, the articles “a,” “an,” “the,” and “the” are intended to mean the presence of one or more elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that additional elements may be present in addition to those listed.

[0020] Industrial automation systems can utilize a controller to output regulated power signals to one or more actuators to control their movement. The controller can be combined with other components within a housing or enclosure to form a motor control center (MCC) that controls the movement of multiple actuators. The MCC enclosure can be divided into one or more vertical sections, each further divided into one or more bins configured to receive units (e.g., variable frequency drives (VFDs), programmable logic controllers (PLCs), programmable automation controllers (PACs), contactors, starters, overload protection components, fuses, circuit breakers, disconnect devices, short-circuit protectors, etc.). Multi-tap cables can be routed through the MCC enclosure and communicatively coupled to units within the MCC, and in some cases, to components within the units, to establish a subnet or network as part of another network of the MCC. If a unit of the MCC is inserted or removed for an excessively long period, the insertion or removal of that unit may interfere with the network and / or subnet.

[0021] The disclosed technology includes trunking and tap connectors for coupling a detachable MCC unit to a multi-tap cable. Specifically, the multi-tap cable can serve as the trunking and may include conductors forming: a single Ethernet (SPE) pair that facilitates data communication between components of the subnet; a switching power (SP) pair that provides power to the components of the subnet; a network power (NP) pair that provides power to the subnet; and a select line that manages communication via the SPE pairs. The trunking and tap connectors include pins that couple the input and output lines of the detachable MCC unit to the SPE pairs and select lines, but allow the SP pairs and NPs to continue uninterruptedly through the trunking. The trunking and tap connectors enable the addition of multiple nodes to the subnet within the detachable MCC unit, allowing various components (e.g., variable frequency drives (VFDs), programmable logic controllers (PLCs), programmable automation controllers (PACs), contactors, starters, overload protection devices, fuses, circuit breakers, disconnect devices, short-circuit protectors, etc.) to be connected to the subnet. In addition, trunking and tap connectors enable detachable MCC units to be coupled to sections decoupled from multi-tap cables without interfering with the network or subnet within the MCC.

[0022] Through introduction, Figure 1 This is a schematic diagram of an example industrial automation system 10, in which the embodiments described herein can be implemented. As shown, the industrial automation system 10 includes a controller 12 and an actuator 14 (e.g., a motor). The industrial automation system 10 may also include a power supply 16 or be coupled to a power supply 16. The power supply 16 may include a generator, a battery (or other power storage device), or an external power grid. Although Figure 1The controller 12 shown is a standalone controller 12, but in a more complex industrial automation system 10, one or more controllers 12 may be integrated with a motor control center (MCC, hereinafter referred to as...) Figure 2 Other components shown and described are combined to control multiple actuators. In this embodiment, controller 12 includes a user interface 18, such as a human-machine interface (HMI), and a control system 20, which may include a memory 22 and a processor 24. Controller 12 may include a cabinet or other enclosures for housing various components of the industrial automation system 10, such as motor starters, disconnect switches, etc.

[0023] Control system 20 can be programmed (e.g., via computer-readable code or instructions stored on memory 22 and configured to be executed by processor 24) to provide signals for driving motor 14. In some embodiments, control system 20 can be programmed according to a specific configuration desired for a particular application. For example, control system 20 can be programmed to respond to external inputs, such as reference signals, alarms, command / status signals, etc. External inputs may originate from one or more relays or other electronic devices. Programming of control system 20 can be accomplished by software configuration or firmware code that can be loaded into the internal memory 22 of control system 20 or programmed via user interface 18 of controller 12. Control system 20 can respond to a defined set of operating parameters. The setting of various operating parameters determines the operating characteristics of controller 12. For example, various operating parameters may determine the speed or torque of motor 14, or may determine how controller 12 responds to various external inputs. Therefore, operating parameters can be used to map control variables within controller 12 or control other devices communicatively coupled to controller 12. These variables may include, for example, speed presets, feedback types and values, calculated gains and variables, algorithm adjustments, status and feedback variables, programmable logic controllers (PLCs) such as control programming, etc.

[0024] In some implementations, the controller 12 may be communicatively coupled to one or more sensors 26 for detecting operating temperature, voltage, current, pressure, flow rate, etc., within the industrial automation system 10. Using feedback data from the sensors, the control system 20 can maintain detailed tracking of various conditions under which the industrial automation system 10 may operate. For example, the feedback data may include conditions such as actual motor speed, voltage, frequency, power quality, alarm conditions, etc.

[0025] As mentioned above, in some complex industrial automation systems 10, one or more controllers and / or other industrial automation components (e.g., variable frequency drives (VFDs), PLCs, programmable automation controllers (PACs), contactors, starters, overload protection components, fuses, circuit breakers, disconnecting devices, short-circuit protectors, etc.) can be combined into a housing or cabinet and referred to as an MCC. Figure 2 This is a front view of an embodiment of the MCC 100. As shown, the MCC 100 includes a housing 102 divided into vertical sections 104, 106, 108, 110, 112, 114, and 116. Each section may be further divided into one or more buckets 118, 120, 122, and 124 that can be configured to receive units. These units may include industrial automation components configured to perform industrial automation functions. Therefore, these units may include, for example, motor controllers, VFDs, PLCs, PACs, contactors, starters, overload protection components, fuses, circuit breakers, disconnecting devices, short-circuit protectors, etc. In some embodiments, the size of each bucket 118, 120, 122, and 124 may be customized to the type of unit that the buckets 118, 120, 122, and 124 are configured to receive. In other embodiments, different MCC 100s may be available with buckets of different sizes pre-configured. As shown, some of the cabinet doors 126 may include a disconnect switch 128 for disconnecting the corresponding unit from the MCC 100. Therefore, to remove the unit, a user can actuate the disconnect switch 128 (e.g., from "on" to "off") to electrically disconnect the unit from the MCC 100. The user can then open the cabinet door 126 and physically remove the unit from the housing 102. If the unit is replaced with a different unit, the new unit can be physically installed in the cabinet 124, the cabinet door 126 closed, and the disconnect switch 128 actuated (e.g., from "off" to "on").

[0026] Units within MCC 100 can be added to a wired subnet by coupling to one or more multi-tap cables extending through MCC housing 102. In some embodiments, one or more multi-tap cables may also extend within the unit to communicatively couple components within the unit. Figure 3 Describing the use of in Figure 2This is a portion of a multi-tap cable 200 used within the MCC 100. The illustrated portion of the multi-tap cable 200 may include one or more terminals 202 positioned along a transmission line 204. Terminals 202 may include slots 206 to facilitate electrical connection of industrial automation devices to the transmission line 204 via tap circuitry (not shown). Nodes may include terminals 202 and respective connected tap circuitry. In some embodiments, terminals 202 may be referred to as “taps,” and portions of the transmission line 204 extending between terminals may be referred to as “trunk” 210. Therefore, the term “multi-tap” in the context of the multi-tap cable 200 refers to the cable 200 having multiple terminals 202 to which components can be connected. In some embodiments, connectors coupled to terminals 202 may allow multiple nodes to be added to the multi-tap cable 200 at a single tap (e.g., multiple nodes may be coupled to the cable in a loop or as a single wire, which is coupled to the multi-tap cable 200 at a single terminal 202). In some embodiments, the multi-tap cable 200 may include a long trunk 210 between taps 202, or may not include taps 202 at all, allowing new taps 202 to be added as needed. Therefore, the disclosed trunk and tap connectors can be used to connect and disconnect detachable MCC units without interfering with the MCC's network or subnet. The transmission line 204 may include electrical conductors 208A to 208G. It should be noted that different numbers of terminals 202 may be used in different embodiments of the multi-tap cable 200 in the MCC 100.

[0027] The multi-tap cable 200 facilitates communication between nodes using various communication protocols. Therefore, the number and arrangement of conductors in the transmission line 204 can vary based on the communication protocol used by the MCC 100. For example, the multi-tap cable 200 can use the Industrial Ethernet Network Protocol (Ethernet / IP). Terminals 202 can each include corresponding tap circuits that facilitate the connection of various industrial automation components to the transmission line 204 of the multi-tap cable 200. Connectors facilitate power transmission and / or communication between the input / output signals of the respective nodes and the transmission line 204 of the multi-tap cable 200.

[0028] The MCC 100 can use multi-tap cables 200 to facilitate data communication between different numbers of nodes in different configurations and directions. For example, the MCC 100 can use one or more multi-tap cables 200 to communicatively connect motor controllers, VFDs, PLCs, PACs, contactors, starters, overload protection components, fuses, circuit breakers, disconnect devices, short-circuit protectors, etc., within the MCC 100. Furthermore, as long as the connection conforms to the communication protocol of the multi-tap cables 200, the nodes can take any shape or form. For example, sensor 26 ( Figure 1(As shown) can be positioned on a tap circuit, and the tap circuit can be connected to slot 206 of terminal 202 to communicate with one or more other nodes connected to the multi-tap cable 200 via transmission line 204.

[0029] Figure 4 A cross-sectional side view depicts an embodiment of the transmission line 204 of a multi-tap cable 200 using the Ethernet / IP protocol. It should be noted that the multi-tap cable 200 is not intended to be limited to the Ethernet / IP protocol or... Figure 4 The conductors 208A to 208G are shown in the illustration. In different embodiments, the multi-tap cable 200 may employ other communication protocols and / or other combinations of conductors. Furthermore, the transmission line 204 may include cables with different wire gauges or conductive materials for different applications.

[0030] Transmission line 204 may include a single pair of Ethernet (SPE) conductors 302, a switching power supply (SP) pair 304, network power (NP) pairs 306A and 306B, and a select line conductor 308. SPE 302 may include a first conductor and a second conductor to enable differential signal transmission. In some embodiments, SPE 302 may be a single pair of Ethernet cables, and SP 304, as well as NP 306A and NP 306B, may carry direct current (DC) power. The SPE 302 conductor may transmit communication signals, and the SP 304 conductor may transmit signals between different nodes in the form of a switching power supply. In some embodiments, SPE 302 and / or SP 304 may deliver power to one or more nodes to power actuators, contactors, and sound generators, etc. The NP 306A and NP 306B conductors may provide power to one or more nodes. In some embodiments, the NP 306A and NP 306B conductors may power the communication circuitry and / or microcontrollers of the respective one or more nodes. Furthermore, the selector conductor 308 can transmit a selector signal to facilitate node identification and configuration. The selector conductor 308 can transmit communication signals and / or facilitate the communication or transmission of power signals via the SPE 302 conductor and / or the SP 304 conductor. For example, the selector conductor 308 may include an identification number associated with the selection of a node on the multi-tap cable 200. It should be noted that in different examples, the node selected by the selector conductor 308 may perform different functions associated with the selected node.

[0031] Return to Figure 3When adding and / or removing units from the bucket of an MCC, users may wish to insert or remove detachable MCC units, which involves adding or removing nodes from a subnet to accommodate the added or removed units without disrupting the network or subnet within the MCC. If units are inserted and / or removed within the MCC for extended periods, the network or subnet within the MCC may become disrupted (e.g., addresses assigned to nodes become confused, management of data transmission via multi-tap cables becomes chaotic, etc.). Therefore, the disclosed implementation includes trunk and tap connectors that function as passive mechanical switches for connecting a set of nodes to and / or disconnecting a set of nodes associated with a detachable MCC unit without disrupting the network. Figure 5A A removable MCC unit 402 comprising one or more nodes is shown, disconnected from the trunk and tap connector 400. As shown, the removable MCC unit 402 includes an input line 404 and an output line 406 communicatively coupled to pin 408, which is not connected to the trunk and tap connector 400 of the multi-tap cable 200. Therefore, the SPE pair 302, SP pair 304, NP pairs 306A, 306B, and select line 308 extend uninterruptedly through the trunk 210.

[0032] Figure 5BAn embodiment of the MCC detachable unit 402 connected to the trunk and tap connector 400 is shown. The trunk and tap connector 400 may be disposed around or otherwise coupled to the trunk 210 of the multi-tap cable 200. In some embodiments, the trunk and tap connector 400 may be permanently mounted on the multi-tap cable 200, while in other embodiments, the trunk and tap connector 400 may pierce, cut through, or otherwise move the insulator disposed around one or more conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200 to electrically couple the unit 402 to one or more conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200. In other embodiments, the trunk and tap connector 400 can electrically couple unit 402 to one or more conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200 by surrounding the trunk 210 and detecting signals transmitted by one or more conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200 without interfering with the insulation disposed around one or more conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200. Figure 5B In the illustrated embodiment, the MCC detachable unit 402 can be coupled to the trunk and tap connector 400 such that the input line 404 of unit 402 is electrically coupled via pin 408 to conductor 208A associated with select line 308 and conductors 208C, 208D associated with SPE pair 302. Similarly, the MCC detachable unit 402 can be coupled to the trunk and tap connector 400 such that the output line 406 of unit 402 is electrically coupled via pin 408 to conductor 208A associated with select line 308 and conductors 208C, 208D associated with SPE pair 302. Therefore, the input line 404, unit 402, and output line 406 can form a loop, and one or more nodes can be added to the subnet without interrupting the MCC network. In some embodiments, connecting the trunk and tap connector 400 to the trunk 210 of the multi-tap cable 200 may interrupt the network within the MCC over extended periods. Therefore, the trunk and tap connector 400 can be configured to electrically couple the input line 404 and output line 406 of the MCC detachable unit 402 to the corresponding conductors in the trunk 210 of the multi-tap cable 200 within a threshold time amount (e.g., 10ms, 20ms, 30ms, 40ms, 50ms, 60ms, 70ms, 80ms, 90ms, 100ms, etc.).

[0033] like Figure 5B As shown, the trunk and tap connector 400 can electrically couple only some conductors 208A, 208C, 208D of the multi-tap cable 200 to the MCC detachable unit 402, while the remaining conductors 208B, 208E, 208F, 208G of the multi-tap cable 200 remain undisturbed. That is, in this embodiment, a device connected to a new node created by the trunk and tap connector 400 can communicate with other components within the MCC using only the SPE pair 302, and then use the select line 308 to manage how data is transmitted via the SPE pair 302. Therefore, because the device connected to the new node may draw power from other sources, the device connected to the new node may not use the SP pair 304 and NP pair 306. In other embodiments, power can be drawn from the SP pair 304 and NP pair 306 without actually electrically coupling to them. Therefore, the trunk and tap connector 400 can be configured simply to electrically couple the MCC detachable unit 402 to the conductors used by the device connected to the new node. However, it should be understood that other implementations are also contemplated whereby the trunk and tap connector 400 electrically couples the MCC detachable unit 402 to more, fewer, or different combinations of conductors 208A, 208B, 208C, 208D, 208E, 208F, 208G of the multi-tap cable 200. For example, in some implementations, the trunk and tap connector 400 may electrically couple to the SP pair 304 and / or the NP pair 306 in addition to the SPE pair 302 and the select line 308.

[0034] Figure 6A and Figure 6B This illustrates how the MCC detachable unit 402 is coupled via trunk and tap connector 400 to one of the conductors 208 in the trunk 210 of the multi-tap cable 200. Specifically, Figure 6A This is a schematic diagram showing the trunk and tap connector 400 without the MCC detachable unit 402 connected. As shown, when the MCC detachable unit 402 is not connected to the trunk and tap connector 400, the first conductor 208 and the second conductor 208 for a given line are in contact with each other, and the signal passes through the trunk and tap connector 400 as if it were passing through the trunk of a multi-tap cable.

[0035] Figure 6BThis is a schematic diagram showing the trunk and tap connector 400 connected to the MCC detachable unit 402. As shown, when pins 408 coupled to input lines 404 and output lines 406 are inserted into the trunk and tap connector 400 (e.g., coupled to a corresponding concave or convex portion of the trunk and tap connector 400 as part of a convex or concave portion of a multi-tap cable), pins 408 move the first conductor 208 and the second conductor 208, decoupling the first conductor 208 and the second conductor 208 from each other, and coupling the first pin 408 coupled to the corresponding input line 404 to the first conductor 208, and coupling the second pin 408 coupled to the corresponding output line 406 to the second conductor 208, thereby creating a loop through the MCC detachable unit 402. For example, as shown and described in more detail below, a multi-tap cable can pass through an MCC detachable unit 402 disposed within a bucket of the MCC, communicatively coupling one or more nodes within the MCC detachable unit 402, which are associated with corresponding components within the MCC detachable unit 402. The trunk and tap connectors 400 can be configured such that the time interval between the decoupling of the first conductor 208 and the second conductor 208 from each other and the coupling of the first pin 408 and the second pin 408 to their respective first conductor 208 and second conductor 208 is short enough to prevent interference with subnets or networks within the MCC. For example, the time interval between the decoupling of the first conductor 208 and the second conductor 208 from each other and the coupling of the first pin 408 and the second pin 408 to their respective first conductor 208 and second conductor 208 can be less than 10ms, 20ms, 30ms, 40ms, 50ms, 60ms, 70ms, 80ms, 90ms, 100ms, etc.

[0036] Similarly, when pins 408 coupled to input line 404 and output line 406 are removed from trunk and tap connector 400 (e.g., the convex or concave portion of the multi-tap cable is decoupled from the corresponding concave or convex portion of trunk and tap connector 400), first pins 408 and second pins 408 are decoupled from the corresponding first conductors 208 and second conductors 208, allowing the first conductors 208 and second conductors 208 to return to their natural state and recouple from each other, so that the signal passes through trunk and tap connector 400 as if it were passing through the trunk of the multi-tap cable. Trunk and tap connector 400 can also be configured such that the time interval between the decoupling of first pins 408 and second pins 408 from the corresponding first conductors 208 and second conductors 208 and the recoupling of first conductors 208 and second conductors 208 from each other is short enough that the subnets or networks within the MCC are not disturbed. For example, the time interval between the decoupling of the first pin 408 and the second pin 408 with the corresponding first conductor 208 and the recoupling of the first conductor 208 and the second conductor 208 with each other can be less than 10ms, 20ms, 30ms, 40ms, 50ms, 60ms, 70ms, 80ms, 90ms, 100ms, etc. Therefore, the MCC detachable unit 402 can be inserted into and removed from the MCC without interfering with the subnets or networks within the MCC.

[0037] Figure 7 A schematic diagram of MCC 100 is shown, in which a removable MCC unit 402, mounted in a barrel 120, is connected to a multi-tap cable 200 via a trunk and tap connector 400. As shown, MCC 100 includes barrels 118, 120, 122, and 124 housing the removable MCC unit 402. Barrels 118, 122, and 124 are connected to a subnet via a trunk and tap connector of the multi-tap cable 200 passing through line 500, and include various devices 502, 504, 506, and 508 connected to each other via the multi-tap cable 200, which has terminals 202 at nodes within barrels 118, 122, and 124. As previously stated, if an operator of MCC 100 wishes to insert or remove barrel 120 without interfering with the subnet, or to add more nodes to the subnet, the operator can utilize the disclosed trunk and tap connector 400. Figure 7In the illustrated embodiment, barrels 120 and 124 include a multi-tap cable 200 forming a loop within barrels 120 and 124, the multi-tap cable 200 being connected to devices 504, 506, and 508 via terminals 202 located at nodes. Devices 502, 504, 506, and 504 may include, for example, motor controllers, VFDs, PLCs, PACs, contactors, starters, overload protection components, fuses, circuit breakers, disconnecting devices, short-circuit protectors, interfaces, indicators, buttons, switches, displays, sensors, etc. Although installed... Figure 7 The MCC removable unit 402 in the shown bins 120 and 124 includes three nodes 202; however, it should be understood that the MCC removable unit 402 installed in bins 118, 120, 122, and 124 of the MCC 100 may include other numbers of nodes 202. For example, embodiments in which the MCC removable unit 402 includes 2, 3, 4, 5, 6, 7, 8, 9, 10, or more nodes are envisioned.

[0038] Figure 8 A schematic diagram of an MCC 100 is shown, comprising two MCC detachable units 402 mounted in two corresponding bins 118, 120, which are connected to a multi-tap cable 200 via a trunk and tap connector 400. As shown, power from a power source 16 and control signals generated by a PLC 510 are provided to a gateway 600. The multi-tap cable 200 extends from the gateway 600 through line 500 to terminal 602. The first trunk and tap connector 400 is coupled to an MCC detachable unit 402 mounted in the first bin 118 and including an interface 502 and device 504. The interface 502 may include, for example, buttons, knobs, switches, indicator lights, meters, displays, touchscreens, etc. The device 504 in the first bin 118 may include, for example, a motor controller, VFD, PLC, PAC, contactor, starter, overload protection device, fuse, circuit breaker, disconnect device, short-circuit protector, interface, indicator, button, switch, display, sensor, etc.

[0039] Similarly, the second trunk line and tap connector 400 can be coupled to the second MCC detachable unit 402, which is installed in the second bucket 120 and includes an interface 502 and device 504. Like the MCC detachable unit 402 installed in the first bucket 118, the interface 502 can include buttons, knobs, switches, indicator lights, meters, displays, touchscreens, etc. However, the interface 502 of the MCC detachable unit 402 installed in the second bucket 120 can be the same as or different from the interface 502 of the MCC detachable unit 402 installed in the first bucket 118. Like the first bucket 118, the device 504 in the MCC detachable unit 402 installed in the second bucket 120 can include, for example, a motor controller, VFD, PLC, PAC, contactor, starter, overload protection component, fuse, circuit breaker, disconnecting device, short-circuit protector, interface, indicator, button, switch, display, sensor, etc. Similarly, the device 504 installed in the MCC detachable unit 402 in the second drum 120 may be the same as or different from the device 504 installed in the MCC detachable unit 402 in the first drum 118. Furthermore, the multi-tap cables 200 in different drums may have different numbers of nodes for different configurations of components. For example, the multi-tap cable 200 in the first drum 118 may include four nodes, while the second multi-tap cable 200 in the second drum 120 may include three nodes, depending on what components and how many new nodes the operator wishes to include.

[0040] Figure 9This is a flowchart of process 700 for connecting a detachable MCC unit to a trunk and tap connector of a multi-tap cable. At block 702, the convex portion of the unit connector can be inserted into the concave portion of the trunk and tap connector. However, it should be understood that implementations in which the convex and concave portions are reversed are also contemplated (e.g., the convex portion is on the unit connector, and the concave portion is on the trunk and tap connector). Furthermore, the unit connector can be a part of a unit housing configured to be inserted into a barrel, a connector coupled to a cable such as a multi-tap cable, or some other configuration. In some implementations, the trunk and tap connector may simply be wrapped around the multi-tap cable or otherwise positioned around it. In other implementations, the trunk and tap connector may be clamped onto the multi-tap cable or otherwise physically coupled to it. At block 704, the connection between the first and second conductors of the trunk and tap connector is broken by a first and second corresponding pin group of the convex portion of the unit connector. For example, the pins of the convex portion of the unit connector can be inserted into the trunk and tap connectors such that the first set of pins and the second set of pins contact the first set of conductors and the second set of conductors, and then force is applied to the first set of conductors and the second set of conductors, forcing the first set of conductors and the second set of conductors to move, thereby breaking the electrical connection between the first set of conductors and the second set of conductors. Thus, at block 706, the first set of pins and the second set of pins, communicatively coupled to the input line and the output line, respectively, are electrically coupled to the SPE pair and the select line. As previously discussed, in some embodiments, the multi-tap cable can be manufactured to attach one or more trunk and tap connectors. In other embodiments, the trunk and tap connectors can be coupled to the multi-tap cable subsequently. For example, the trunk and tap connectors can pierce, cut through, or otherwise move the insulator disposed around one or more conductors of the multi-tap cable to electrically couple the unit to one or more conductors of the multi-tap cable. In other embodiments, the trunk and tap connectors can electrically couple the unit to one or more conductors of the multi-tap cable without interfering with the insulator disposed around one or more conductors of the multi-tap cable. At block 708, components can be connected to nodes within the detachable MCC unit, which is coupled to a network or subnet via trunk lines and tap connectors. As previously described, connected components may include, for example, motor controllers, VFDs, PLCs, PACs, contactors, starters, overload protection devices, fuses, circuit breakers, disconnect devices, short-circuit protectors, interfaces, indicators, buttons, switches, displays, sensors, etc. The MCC can then be operated to control one or more actuators in an industrial automation system.

[0041] The disclosed technology includes trunking and tap connectors for coupling a detachable MCC unit to a multi-tap cable. Specifically, the multi-tap cable can serve as the trunking and may include conductors forming: a single Ethernet (SPE) pair that facilitates data communication between components of the subnet; a switching power (SP) pair that provides power to the components of the subnet; a network power (NP) pair that provides power to the subnet; and a select line that manages communication via the SPE pairs. The trunking and tap connectors include pins that couple the input and output lines of the detachable MCC unit to the SPE pairs and select lines, but allow the SP pairs and NPs to continue uninterruptedly through the trunking. The trunking and tap connectors enable the addition of multiple nodes to the subnet within the detachable MCC unit, allowing various components (e.g., variable frequency drives (VFDs), programmable logic controllers (PLCs), programmable automation controllers (PACs), contactors, starters, overload protection devices, fuses, circuit breakers, disconnect devices, short-circuit protectors, etc.) to be connected to the subnet. In addition, trunking and tap connectors enable detachable MCC units to be coupled to sections decoupled from multi-tap cables without interfering with the network or subnet within the MCC.

[0042] While only certain features of this disclosure have been illustrated and described herein, many modifications and alterations will be made by those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and alterations falling within the true spirit of the embodiments described herein.

[0043] The techniques proposed and claimed herein are referenced and applied to specific examples of material objects and actual properties that clearly improve upon the art and are therefore not abstract, intangible, or purely theoretical. Furthermore, if any claim appended to this specification contains one or more elements designated as "means for [performing] [function]..." or "steps for [performing] [function]...", it is intended that such elements be interpreted according to 35U.SC112(f). However, for any claim containing elements designated in any other manner, it is intended that such elements not be interpreted according to 35U.SC112(f).

Claims

1. A multi-tap cable configured to be installed within a motor control center of an industrial automation system, comprising: a trunk; a first connector coupled to a first end of the trunk, wherein the first connector includes a first terminal configured to be communicatively coupled to a first unit installed in a first tank of the motor control center; and a second connector coupled to a second end of the trunk, wherein the second connector is configured to be communicatively coupled to a second unit installed in a second tank of the motor control center, wherein the second unit comprises a motor control center removable unit, and wherein the second connector is configured to couple the motor control center removable unit to the multi-tap cable to facilitate data communication of a network or subnetwork of the motor control center and decouple the motor control center removable unit from the multi-tap cable; wherein the second connector is further configured to electrically connect to a subset of conductors of a total number of conductors of the multi-tap cable to form a loop from an input pin of the motor control center removable unit through the motor control center removable unit to an output pin of the motor control center removable unit while a remaining number of conductors of the multi-tap cable remain unchanged to connections of the multi-tap cable; and wherein the subset of conductors is a number of conductors used by the second unit to communicatively couple to the second connector.

2. The multi-tap cable of claim 1, wherein, the total number of conductors of the multi-tap cable comprises: a single pair Ethernet pair; a switching power supply pair; a network power supply pair; and a select line.

3. The multi-tap cable of claim 2, wherein, the single pair Ethernet pair includes a first conductor and a second conductor, wherein the switching power supply pair includes a third conductor and a fourth conductor, wherein the network power supply pair includes a fifth conductor and a sixth conductor, and wherein the select line includes a seventh conductor.

4. The multi-tap cable of claim 3, wherein, the communicatively coupled subset of conductors of the second connector includes the first conductor, the second conductor, and the seventh conductor.

5. The multi-tap cable of claim 4, wherein, the second connector includes: a first input line communicatively coupled to the first conductor; a second input line communicatively coupled to the second conductor; a third input line communicatively coupled to the seventh conductor; a first output line communicatively coupled to the first conductor; a second output line communicatively coupled to the second conductor; and a third output line communicatively coupled to the seventh conductor.

6. The multi-tap cable of claim 1, wherein, the motor control center removable unit includes one or more motor controllers, one or more variable frequency drives, one or more programmable logic controllers, one or more programmable automation controllers, one or more contactors, one or more motor starters, one or more overload protection components, one or more fuses, one or more circuit breakers, one or more disconnect switches, one or more short circuit protectors, or a combination thereof.

7. The multi-tap cable of claim 1, wherein, the motor control center removable unit includes one or more buttons, one or more knobs, one or more switches, one or more indicator lights, one or more gauges, one or more displays, one or more touchscreens, or a combination thereof.

8. A first connector configured to communicatively couple a trunk of a multi-tap cable to a motor control center removable unit of a motor control center for an industrial automation system, wherein, the trunk of the multi-drop cable is communicatively coupled to a second connector comprising a first terminal, wherein the first connector comprises: one or more input pins communicatively coupled to one or more conductors extending through the trunk of the multi-drop cable; and one or more output pins communicatively coupled to one or more conductors extending through the trunk of the multi-drop cable; wherein the first connector is configured to connect a plurality of nodes associated with the motor control center removable unit installed in the barrel of the motor control center to a network or subnetwork of the motor control center; wherein the first connector is further configured to electrically connect to a subset of conductors of a total number of conductors of the multi-drop cable to form a loop from an input pin of the motor control center removable unit through the motor control center removable unit to an output pin of the motor control center removable unit while a remaining number of conductors of the multi-drop cable remain unchanged to connections of the multi-drop cable; and wherein the subset of conductors is a number of conductors used by the equipment to communicatively couple with the plurality of nodes associated with the motor control center removable unit installed in the barrel of the motor control center.

9. The first connector of claim 8, wherein, the total number of conductors of the multi-drop cable comprises: a single pair Ethernet pair; a switching power supply pair; a network power supply pair; and a select line.

10. The first connector of claim 9, wherein, the single pair Ethernet pair comprises a first conductor and a second conductor, wherein the switching power supply pair comprises a third conductor and a fourth conductor, wherein the network power supply pair comprises a fifth conductor and a sixth conductor, and wherein the select line comprises a seventh conductor.

11. The first connector of claim 10, wherein, the first connector is communicatively coupled to the first conductor, the second conductor, and the seventh conductor.

12. The first connector of claim 11, wherein: the one or more input pins comprise: a first input pin communicatively coupled to the first conductor; a second input pin communicatively coupled to the second conductor; and a third input pin communicatively coupled to the seventh conductor; and the one or more output pins comprise: a first output pin communicatively coupled to the first conductor; a second output pin communicatively coupled to the second conductor; and a third output pin communicatively coupled to the seventh conductor.

13. The first connector of claim 8, wherein, the motor control center removable unit comprises one or more motor controllers, one or more variable frequency drives, one or more programmable logic controllers, one or more programmable automation controllers, one or more contactors, one or more motor starters, one or more overload protection components, one or more fuses, one or more circuit breakers, one or more disconnect switches, one or more short circuit protectors, or a combination thereof.

14. The first connector of claim 8, wherein, the motor control center removable unit comprises one or more buttons, one or more knobs, one or more switches, one or more indicator lights, one or more gauges, one or more displays, one or more touchscreens, or a combination thereof.

15. An industrial automation system comprising: a motor control center comprising: a first barrel; and a second barrel; and The multi-tap cable according to any one of claims 1-7.

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