Systems and methods for coordinating insertion and / or removal of redundant input / output components

Abstract

Systems and methods related to coordinating insertion and / or removal of redundant input / output components. A non-transitory computer-readable medium includes computer-executable instructions that, when executed by one or more processors associated with a first input / output (I / O) component in an industrial automation system, cause the processors to perform operations. The first I / O component can operate in a separate duplex ("suplex") mode of operation. The operations include detecting a second I / O component in the industrial automation system; determining that a first hardware configuration, a first software configuration, or both, associated with the first I / O component, and a second hardware configuration, a second software configuration, or both, associated with the second I / O component, are compatible; and reconfiguring the first I / O component to operate in a duplex mode of operation.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to coordinating operational modes of redundant input / output (I / O) components. More specifically, embodiments of the present disclosure relate to inserting and / or removing I / O components from an industrial automation system, and coordinating reconfiguration of one or more I / O components to maintain communication with or control over one or more I / O devices in the industrial automation system. BACKGROUND

[0002] Industrial automation systems can be used to provide automated control over one or more actuators. For example, a controller of an industrial automation system can output a conditioned power signal to an actuator to control activity of the actuator. Input / output (I / O) components can facilitate communication between the controller and the actuator or other devices within the industrial automation system. In particular industrial automation systems, redundant I / O components can be used to maintain communication between the controller and the actuator or other devices. However, maintaining redundant I / O components can require removal of a particular I / O component of a pair of redundant I / O components and insertion of a replacement I / O component. Such maintenance can interrupt communication between the controller and the actuator or other devices. Accordingly, it is desirable to facilitate maintenance or replacement of redundant I / O components in an industrial automation system to minimize interruption of communication between the controller and other devices in the industrial automation system.

[0003] This section is intended to introduce the reader to various aspects of art that can be related to various aspects of the technology disclosed herein and is not intended to limit the scope of the claimed technology. The discussion below is intended to provide background information to facilitate a better understanding of the various aspects of the disclosure. Accordingly, it should be understood that these statements are to be read in this light and not as admissions of prior art. SUMMARY

[0004] The following presents a summary of certain implementations disclosed herein. It should be appreciated that this presentation is merely an

[0005] In one implementation, an input / output (I / O) system of an industrial automation system includes a terminal block, a first I / O component, and a second I / O component. The terminal block includes terminals that can be coupled to respective I / O components. The first I / O component and the second I / O component are removably coupled to the set of terminals. The first I / O component and the second I / O component operate in a duplex mode of operation. The first I / O component can perform a first set of operations including receiving a signal indicating that the first I / O component is unlocked from the terminal block, generating a schedule for disengaging the first I / O component from the terminal block, sending the schedule to the second I / O component, and disengaging from the set of terminals based on the schedule. The second I / O component can perform a second set of operations including receiving the schedule from the first I / O component, and reconfiguring the second I / O component to operate in a single duplex ("suplex") mode of operation.

[0006] In another implementation, a method includes receiving, by a first input / output (I / O) component removably coupled to a terminal block, a signal indicating that the first I / O component is unlocked from the terminal block, generating, by the first I / O component, a schedule for disengaging the first I / O component from the terminal block, sending, by the first I / O component, the schedule to a second I / O component, and disengaging, by the first I / O component, from a set of terminals associated with the terminal block based on the schedule. The method also includes reconfiguring, by the second I / O component, an operational configuration associated with the second I / O component to a single duplex ("suplex") mode of operation based on the schedule.

[0007] In yet another implementation, a non-transitory computer-readable medium includes computer-executable instructions that, when executed by one or more processors associated with a first input / output (I / O) component in an industrial automation system, cause the processors to perform operations. The first I / O component can operate in a single duplex ("suplex") mode of operation. The operations include detecting a second I / O component in the industrial automation system, determining that a first hardware configuration, a first software configuration, or both, associated with the first I / O component are compatible with a second hardware configuration, a second software configuration, or both, associated with the second I / O component, and reconfiguring the first I / O component to operate in a duplex mode of operation. BRIEF DESCRIPTION OF DRAWINGS

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood with reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals represent like parts, wherein:

[0009] Figure 1 is a schematic diagram of an industrial automation system according to an embodiment;

[0010] Figure 2 is a schematic diagram of a modular input / output (I / O) system that can be used in an industrial automation system according to an embodiment; Figure 1

[0011] Figure 3 is a block diagram of a reconfiguration process associated with a redundant I / O component pair according to an embodiment, wherein the redundant I / O component pair is associated with an I / O system of Figure 2 ; and

[0012] Figure 4 is a flowchart of a method for coordinating a disengagement of a first redundant I / O component in a redundant I / O component pair of Figure 3 and a reconfiguration of a second redundant I / O component in the redundant I / O component pair according to an embodiment;

[0013] Figure 5 is a block diagram of a reconfiguration process associated with a replacement I / O component and a partner I / O component according to an embodiment, wherein the replacement I / O component and the partner I / O component are associated with an I / O system of Figure 2 ; and

[0014] Figure 6 is a block diagram of a pairing process of a replacement I / O component and a partner I / O component of Figure 5 according to an embodiment. DETAILED DESCRIPTION

[0015] One or more specific embodiments of the present disclosure will be described below. To provide a concise description of these embodiments, all features of an actual implementation can not be described in the specification. It should be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made that, regardless of how these decisions are made, will result in the development of the implementation. These implementation-specific decisions can materially affect the nature of the implementation, and these implementations can be manifested differently, depending on the specific implementation. Furthermore, it should be appreciated that the development of the implementations can be complex and time consuming, but can also benefit from automation.

[0016] ​In introducing elements of various embodiments of the present disclosure, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" and the like are inclusive and are intended to mean that there are additional elements beyond those listed. One or more specific embodiments of the present disclosure described herein will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation can not be described in the specification. It should be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made that will vary from one implementation to another. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

[0017] As described above, redundant I / O components within an industrial automation system can be used by a connection initiator (e.g., a controller) in the industrial automation system to maintain communication with and control of one or more devices. However, maintenance of the redundant I / O components can require removal of a particular I / O component in a pair of redundant I / O components and / or insertion of a replacement I / O component. Such maintenance can interrupt the control of device operations by the connection initiator.

[0018] Accordingly, embodiments of the present disclosure generally provide for seamless switching between different modes of operation associated with partner I / O channels associated with a redundant I / O component pair in an industrial automation system in a seamless (e.g., disturbance-free) manner. For example, each redundant I / O component in a redundant I / O component pair can include one or more isolated channels. Each isolated channel in a first redundant I / O component of a redundant I / O component pair has a partner isolated channel in a second redundant I / O component of the redundant I / O component pair. Each partner isolated channel pair between the redundant I / O component pair generally operates in a duplex mode of operation such that each partner isolated channel pair coordinates performance of a particular operation to maintain communication or control of a respective device by a connection initiator in the industrial system. However, if a failure occurs on a first channel of a partner isolated channel pair, a second channel of the partner isolated channel pair that did not fail can switch to a simplex operation mode (e.g., a single duplex mode of operation) such that the second channel performs the particular operation without coordination with the first channel. In this way, the second channel can take over full performance of the operation while the first channel is under maintenance. Moreover, because each channel in each redundant I / O component is isolated from one another, other partner isolated channel pairs between the redundant I / O component pair can continue to operate in a duplex mode of operation.

[0019] Further, maintaining a redundant I / O component with a failed channel (e.g., a first redundant I / O component of a pair of redundant I / O components) can require removal of the first redundant I / O component from the industrial automation system. For example, a maintenance technician can remove the first redundant I / O component from a base (e.g., a removable terminal block) in the industrial automation system by performing an actuator to unlock the first redundant I / O component from the base. Upon receiving an indication that the first redundant I / O component is being removed from the base, but before the first redundant I / O component has been physically removed from the base, the first redundant I / O component can initiate a reconfiguration process associated with each partner isolated channel pair in the pair of redundant I / O components. In particular, the isolated channels of each partner isolated channel pair associated with the second redundant I / O component can switch their respective operating modes to a separate duplex operating mode such that the isolated channels of the second redundant I / O component perform their respective operations without coordination with their respective partner channels in the first redundant I / O component. In this way, the reconfiguration process can facilitate a seamless (e.g., disturbance-free) transition between the duplex operating mode and the separate duplex operating mode for each isolated channel of the second redundant I / O component to minimize any disruption to communications or control of devices in the industrial automation system by the connection initiators when the first redundant I / O component is removed from the industrial automation system.

[0020] As described above, a maintenance technician can insert a third I / O component (e.g., a replacement I / O component) into the base (e.g., the removable terminal block) to replace the first redundant I / O component in the pair of redundant I / O components. For example, upon receiving an indication that the replacement redundant I / O component is being inserted into the base, the replacement redundant I / O component can initiate a second reconfiguration process associated with each partner isolated channel pair between the replacement redundant I / O component and the second redundant I / O component. In particular, the isolated channels of each partner isolated channel pair between the replacement redundant I / O component and the second redundant I / O component can switch to a duplex operating mode such that each partner isolated channel pair coordinates performance of particular operations to maintain communications or control of respective devices in the industrial system by the connection initiators. In this way, the second reconfiguration process can facilitate a seamless (e.g., disturbance-free) transition between the separate duplex operating mode of each isolated channel of the second redundant I / O component and the duplex operating mode of each partner isolated channel pair between the second redundant I / O component and the replacement redundant I / O component when the replacement I / O component is inserted into the industrial automation system.

[0021] By way of introduction, Figure 1is a schematic diagram of an industrial automation system 10. As shown, the industrial automation system 10 includes a controller 12 (i.e., a connection initiator) and an actuator 14 (e.g., a motor). The industrial automation system 10 can also include, or be coupled to, a power source 16. The power source 16 can include a generator, a battery (or other power storage device), or an external power grid. While the controller 12 shown is a standalone controller 12, in more complex industrial automation systems 10, one or more controllers 12 can be combined with other components in a motor control center (MCC) to control multiple actuators. In the present embodiment, the controller 12 includes a user interface 18, such as a human-machine interface (HMI), and a control system 20, which can include a memory 22 and a processor 24. Figure 1

[0022] The control system 20 can be programmed (e.g., by computer readable code or instructions stored on the memory 22 and configured to be executed by the processor 24) to provide signals for driving the motor 14. In particular embodiments, the control system 20 can be programmed according to a specific configuration required for a particular application. For example, the control system 20 can be programmed to respond to external inputs, such as reference signals, alarms, command / state signals, etc. The external inputs can originate from one or more relays or other electronic devices (e.g., sensors 26). Programming of the control system 20 can be accomplished by software configuration or by firmware code that can be loaded into the internal memory 22 of the control system 20 or programmed through the user interface 18 of the controller 12. The control system 20 can respond to a defined set of operating parameters. The settings of the various operating parameters determine the operating characteristics of the controller 12. For example, the various operating parameters can determine the speed or torque of the motor 14, or can determine how the controller 12 responds to various external inputs (e.g., from the sensors 26). Likewise, the operating parameters can be used to map control variables within the controller 12 or other devices communicatively coupled to the controller 12. For example, these variables can include speed presets, feedback types and values, computational gains and variables, algorithm adjustments, status and feedback variables, programmable logic controllers (PLCs) such as control programming, etc.

[0023] In some embodiments, the controller 12 can be communicatively coupled to one or more sensors 26 for detecting operating temperatures, voltages, currents, pressures, flows, etc. within the industrial automation system 10. With feedback data from the sensors 26, the control system 20 can maintain detailed tracking of the various states in which the industrial automation system 10 is operating. For example, the feedback data can include various states such as actual motor speed, voltage, frequency, power quality, alarm status, etc.

[0024] ​Figure 2 is for Figure 1 A diagram of a modular input / output (I / O) system 100 of the industrial automation system 10 shown in FIG. 1 is shown in FIG. 2. As shown, the modular I / O system 100 includes a network adapter 102 in communication with a controller 12 (i.e., a connection initiator) over a network 104 (e.g., an Ethernet / IP network or other industrial automation network) to enable the network adapter 102 to receive data from, send data to, and otherwise communicate with the controller 12. For example, the controller 12 can be a programmable logic controller or PLC. The network adapter 102 includes a network adapter base 106, a network adapter component 108 (e.g., a network adapter module), a network connector 110, and a power connector 112. In some embodiments, the network adapter 102 can also include a power conditioning circuit 114. The network adapter base 106 can be mounted (e.g., permanently or removably coupled) to a rail or a board 116. The network adapter component 108 can be removably coupled to the network adapter base 106 and include communication circuitry for communicating with the controller 12 over the network connector 110 and the network 104 and / or with other I / O banks 118 coupled to the rail or board 116. Thus, the network adapter component 108 can be configured to manage communications within the I / O system (e.g., between the network adapter 102 and various other I / O banks 118) and / or between the I / O system 100 and various other components of the industrial automation system, including, for example, the controller 12. The power connector 112 can be configured to receive power from a power source (which can or can not be the same power source 16) that provides power to the network adapter 102 and one or more other I / O banks 118 coupled to the rail or board 116. In embodiments having the power conditioning circuit 114, the power conditioning circuit 114 can be configured to condition power received through the power connector 112 from the power source 16 by amplifying the power signal, attenuating the power signal, boosting or reducing the power signal, inverting the power signal, applying one or more filters to the power signal, converting a direct current (DC) power signal to an alternating current (AC) power, converting an AC power signal to a DC power, and the like. Figure 1

[0025] ​Each of the one or more other I / O groups 118 can include an I / O base 120, one or more I / O components 122, 123 (e.g., I / O modules), and a terminal block 124 (e.g., a removable terminal block or "RTB"). The I / O base 120 can also be mounted (e.g., permanently or removably coupled) to the rail or plate 116. The other I / O groups 118 can be communicatively coupled to each other in series and to the network adapter 102 via a multi-contact connector 126, forming a backplane 128 and enabling communication with the controller 12 and one or more other I / O devices 132 via I / O lines 136. The I / O components 122, 123 can be removably coupled to the I / O base 120 (e.g., via the terminal block 124), thereby enabling communication between the I / O components 122, 123 and the controller 12 via the network adapter 102 and the backplane 128.

[0026] The I / O components 122, 123 can be configured to perform one or more specialized industrial automation input / output functions, such as DC input, DC output, AC input, AC output, analog input and / or output, resistance temperature detector (RTD) and / or thermocouple input, output signal to control an actuator, etc. For example, the I / O components 122, 123 can facilitate communication with or control of the one or more I / O devices 132 by the controller 12. As Figure 2 shown, the I / O components 122, 123 can operate as a redundant pair of I / O components 122, 123. For example, each I / O component 122, 123 can include one or more isolated channels that have corresponding partner isolated channels in the other I / O component 122, 123. Each partner isolated channel pair between the pair of I / O components can operate in a duplexed mode of operation or a separate duplex (i.e., "suplex") mode of operation. In the duplexed mode of operation, one or more partner isolated channel pairs between the I / O components 122, 123 can coordinate performance of one or more corresponding specialized industrial automation input / output operations. In the separate duplex mode of operation, one or more isolated channels in each I / O component 122, 123 can perform corresponding specialized industrial automation input / output operations without coordination with a partner isolated channel. Further details regarding operation of the isolated channels in the I / O components 122, 123 will be discussed below with reference to Figure 3 FIGS. 5-7.

[0027] Referring again to Figure 2Junction box 124 may include cage clips, spring clips, push-in terminals, screw terminals, or other wiring connectors 130 configured to couple to field wiring associated with field I / O devices 132 (e.g., sensors, flow meters, switches, probes, thermocouples, RTDs, encoders, actuators, etc.) that are associated with a process or machine controlled by controller 12. In some embodiments, junction box 124 may be a separate structure assembled and coupled to I / O base 120. In other embodiments, junction box 124 may be a component of I / O base 120. Different implementations / configurations of junction box 124 may be used depending on the specific configuration of the field device wiring connectors 130 (e.g., having different common terminals, ground connections, voltage supply terminals, etc.). The I / O group 118 of junction box 124 may also include a power connector 112 to receive power from a power source (which may or may not be a power source). Figure 1 The controller 12 receives power from the same power source 16 shown, which supplies power to I / O group 118 and / or I / O devices 132 (e.g., sensors, actuators, etc.) communicatively coupled to I / O group 118. Each installed I / O component 122, 123 communicates with the field device wiring connector 130 of the same I / O base 120, which is physically coupled to I / O components 122, 123 (e.g., via junction box 124). Input / output data is provided between the controller 12 and the I / O devices 132 connected to the respective I / O base 120 via backplane 128, network adapter component 108, and I / O components 122, 123. In some embodiments, network adapter 102 and I / O group 118 can be coupled to rail or board 116 via a corresponding backplane switch 134, sometimes referred to as a bus interface module (BIM), which facilitates electrical connections between the various components of backplane switch 128 (e.g., network adapter 102, I / O group 118, rail 116, etc.). In some embodiments, multi-contact connector 126 and backplane switch 128 can be different components. In other embodiments, the functions of multi-contact connector 126 and backplane switch 128 can be performed by the same component.

[0028] like Figure 2 As shown, backplane 128 is a circuit that sequentially couples network adapter 102 and adjacent I / O groups 118 via connectors 126 and / or backplane switches 134. For example, the backplane circuit 128 described above is established using a backplane data communication protocol for adapter 102 and the backplane switches 134 for each I / O group 118.

[0029] Considering the above, Figure 3Block diagram 200 illustrates the reconfiguration process associated with redundant I / O components 122, 123 after a failure of the first redundant I / O component 122 in the redundant I / O component pair. As described above, the redundant I / O components 122, 123 can facilitate communication or control of one or more I / O devices 132 by a connection initiator (e.g., controller 12) in the industrial automation system 10. For example, the first redundant I / O component 122 in the redundant I / O component pair 122, 123 may include isolation channels 202, 204, 206, 208, 210, 212, 214, 216, while the second redundant I / O component 123 in the redundant I / O component pair 122, 123 may include isolation channels 203, 205, 207, 209, 211, 213, 215, 217. Although Figure 3 Each redundant I / O component 122, 123 is shown to include eight isolation channels. It should be understood that in other embodiments, each redundant I / O component 122, 123 may have any suitable number of isolation channels. In any case, each isolation channel 202, 204, 206, 208, 210, 212, 214, 216 in the first redundant I / O component 122 has a partner isolation channel 203, 205, 207, 209, 211, 213, 215, 217 in the second redundant I / O component 123. Figure 3 As shown, for example, the isolation channel 202 of the first redundant I / O component 122 and the isolation channel 203 of the second redundant I / O component 123 are buddy isolation channels, the isolation channel 204 of the first redundant I / O component 122 and the isolation channel 205 of the second redundant I / O component 123 are buddy isolation channels, and so on.

[0030] like Figure 3 As shown in box 200A, each buddy isolation channel pair (e.g., isolation channel 202 and isolation channel 203) between the first redundant I / O component 122 and the second redundant I / O component 123 can operate in a full-duplex operation mode to perform dedicated industrial automation input / output operations. Box 200A may correspond to the "normal" state of the redundant I / O component pairs 122, 123 in the industrial automation system 10. For example, the redundant I / O component pairs 122, 123 can operate in the "normal" state when none of the isolation channels (e.g., 202, 203) of the redundant I / O component pairs 122, 123 are faulty.

[0031] In particular embodiments, in a duplex mode of operation, controller 12 can send commands to I / O devices 132 in industrial automation system 10 through network adapter 102 and redundant I / O components 122, 123. In particular, network adapter 102 can receive commands from controller 12 and relay the commands to redundant I / O components 122, 123. Upon receiving respective commands from network adapter 102 at each redundant I / O component 122, 123, a pair of partner isolation channels (e.g., 202, 203) between redundant I / O components 122, 123 can coordinate to perform specialized industrial automation input / output operations that facilitate execution of the commands by I / O devices 132. For example, each partner isolation channel (e.g., 202, 203) can send an output signal indicative of the command to I / O devices 132.

[0032] Additionally, or alternatively, a pair of partner isolation channels (e.g., 202, 203) between redundant I / O components 122, 123 can communicate input data (e.g., sensor data) from I / O devices 132 to controller 12 through network adapter 102. For example, each partner isolation channel (e.g., 202, 203) can receive (e.g., listen for) input data from I / O devices 132 and communicate with each other to compare corresponding values within the received input data received by each partner isolation channel (e.g., 202, 203). Upon agreement by the pair of partner isolation channels (e.g., 202, 203) on a value to send to network adapter 102, each partner isolation channel (e.g., 202, 203) of redundant I / O components 122, 123 sends a signal indicative of the agreed value to network adapter 102. Network adapter 102 can then send a signal indicative of the received value to controller 12.

[0033] As described above, during operation of each pair of partner isolation channels (e.g., isolation channel 202, isolation channel 203) between redundant I / O components 122, 123, a particular isolation channel (e.g., 206) can fail or otherwise become disengaged. For example, an isolation channel can fail due to a loss of power, an overload of power, a short circuit in a circuit, a firmware error, etc. In particular embodiments, an isolation channel can become disengaged if the isolation channel is not configured or the isolation channel has a configuration that conflicts with that of its partner isolation channel. For example, as described above, isolation channel 202 can be configured to send a signal indicative of a value of 1 to network adapter 102, while isolation channel 203 can be configured to send a signal indicative of a value of 0 to network adapter 102. If isolation channel 202 fails or becomes disengaged, isolation channel 203 can send a signal indicative of a value of 0 to network adapter 102, which can be inconsistent with the value of 1 sent by isolation channel 202. In particular embodiments, network adapter 102 can detect the inconsistency in the values sent by isolation channels 202, 203 and can send a signal to controller 12 indicating that an inconsistency has been detected. In particular embodiments, controller 12 can determine that an isolation channel has failed or become disengaged based on the signal received from network adapter 102. Figure 3As shown in block 200B, in response to a failure occurring in the isolated channel 206 of the redundant I / O component 122, the partner isolated channel 207 in the redundant I / O component 123 can switch to a solo-duplex mode of operation to enable the partner isolated channel 207 in the redundant I / O component 123 to perform dedicated industrial automation input / output operations without coordination with the failed isolated channel 206. In particular embodiments, the isolated channel 207 in the redundant I / O component 123 can receive a signal from the isolated channel 206 and / or the redundant I / O component 122 indicating the failure in the isolated channel 206. Upon receiving the signal, the isolated channel 207 can reconfigure itself to operate in the solo-duplex mode of operation. As described above, the dedicated industrial automation input / output operations can facilitate communication or control of an I / O device (e.g., the I / O device 132) between the controller 12 and the I / O device. Moreover, since each partner isolated channel (e.g., 202 and 206, 203 and 207) in each redundant I / O component 122, 123 is isolated from one another, the other isolated channel pair between the redundant I / O component 122, 123 pair can continue to operate in a duplex mode of operation.

[0034] Thereafter, during maintenance of the redundant I / O component 122, a maintenance technician can remove the redundant I / O component 122 with the failed isolated channel 206. As shown in block 200D, the maintenance technician can replace the redundant I / O component 122 with a new redundant I / O component 122. In particular embodiments, the new redundant I / O component 122 can be identical to the redundant I / O component 122 that was removed. In other embodiments, the new redundant I / O component 122 can be different from the redundant I / O component 122 that was removed. For example, the new redundant I / O component 122 can include a different number of isolated channels than the redundant I / O component 122 that was removed. In other embodiments, the new redundant I / O component 122 can include a different number of I / O devices than the redundant I / O component 122 that was removed. Figure 3 As shown in block 200C, each redundant I / O component 122, 123 can include an actuator 218, 219 that enables a maintenance technician to unlock or lock the respective redundant I / O component 122, 123 in the terminal block 124. In particular embodiments, the maintenance technician can rotate the actuator 218, 219 a quarter turn to lock or unlock the respective redundant I / O component 122, 123 relative to the terminal block 124. However, it should be noted that in other embodiments, any other suitable locking mechanism can be used to secure the redundant I / O component 122, 123 to the terminal block 124. For example, in some embodiments, a locking tab can be used to enable the redundant I / O component 122, 123 to be snap-secured to the terminal block 124 or to enable the redundant I / O component 122, 123 to be released from the terminal block 124 after disengaging the locking tab.

[0035] In any case, when the maintenance technician begins to unpin the redundant I / O component 122 with the failed channel 206 from the terminal block 124, the redundant I / O component 122 can receive a signal from the actuator 218 indicating that the redundant I / O component is unpinned. In some embodiments, the actuator 218 can be communicatively coupled to a sensor that continuously or intermittently generates a signal indicating whether the actuator 218 is in a pinned or unpinned position. Upon receiving the signal from the actuator 218 indicating that the redundant I / O component 122 is unpinned, the redundant I / O component 122 can trigger a reconfiguration process to switch the remaining isolated channels (e.g., 203, 205, 209, 211, 213, 215, 217) of the redundant I / O component 123 to a separate duplex mode of operation before the redundant I / O component 122 is removed from the terminal block 124.

[0036] In particular embodiments, in the separate duplex mode of operation, the controller 12 can send commands to the I / O devices in the industrial automation system 10 through the network adapter 102 and the redundant I / O component 123. In particular, upon receiving a command from the controller 12, the network adapter 102 can relay the command to the redundant I / O component 122 with the failed channel 206 and to the redundant I / O component 123. Upon receiving the command from the network adapter 102, the isolated channel (e.g., 207) of the redundant I / O component 123 can perform a dedicated industrial automation input / output operation that facilitates the execution of the command by the I / O device 132. While the redundant I / O component 122 with the failed channel 206 receives the command from the network adapter 102, the failed channel (e.g., 206) of the redundant I / O component 122 does not coordinate the execution of the dedicated industrial automation input / output operation with the isolated channel (e.g., 207) of the redundant I / O component 123 because the isolated channel (e.g., 207) is operating in the separate duplex mode of operation. That is, the redundant I / O component 122 can still receive the command from the network adapter 102 to perform the dedicated industrial automation input / output operation through the failed channel 206, but the redundant I / O component 122 does not perform the dedicated industrial automation input / output operation.

[0037] Additionally, or alternatively, the isolated channel (e.g., 207) of the redundant I / O component 123 can communicate input data (e.g., sensor data) from the I / O device 132 to the controller 12 through the network adapter 102. For example, the isolated channel (e.g., 207) can receive (e.g., listen for) input data from the I / O device 132 and send a signal to the network adapter 102 indicating one or more values of the input data without communicating with the redundant I / O component 122 with the failed channel 206. The network adapter 102 can then send a signal to the controller 12 indicating the received values.

[0038] After the reconfiguration process of the redundant I / O component 123 is complete, the redundant I / O component 122 with the failed channel 206 can be decoupled from the terminal block 124. For example, the redundant I / O component 122 can be physically decoupled from one or more terminals associated with the terminal block 124 such that the redundant I / O component 122 is no longer in communication with the network adapter 102 or the corresponding I / O device 132. In this way, the reconfiguration process can facilitate a seamless (e.g., disturbance-free) transition between the duplexed mode of operation of each partner isolated channel pair (e.g., 202, 203) and the individual duplexed mode of operation of each isolated channel (e.g., 203) of the redundant I / O component 123 that is not removed by the technician. As used herein, a “disturbance-free” transition refers to a duration of the reconfiguration process that is less than 5 milliseconds (ms) or a loss of communication between the controller 12 and the I / O device 132 does not occur. Additional details describing the reconfiguration process are described below with respect to Figure 4 After the reconfiguration process is complete, the maintenance technician can remove the redundant I / O component 122 with the failed channel 206. As shown in block 200D of FIG. 2, the redundant I / O component 122 with the failed channel 206 has been removed from the terminal block 124 and the redundant I / O component 123 (e.g., each isolated channel of the redundant I / O component 123) is operating in the individual duplexed mode of operation. Figure 3

[0039] With the foregoing in mind, Figure 4 ​A flowchart of a method 250 for coordinating the disengagement of a redundant I / O component 122 with a failed channel 206 and reconfiguring one or more isolated channels (e.g., 203) of a redundant I / O component 123 from a duplexed mode of operation to a separate duplexed mode of operation is shown. For example, the method 250 can be performed by the redundant I / O components 122, 123 after the redundant I / O component 122 with the failed channel 206 receives a signal indicating that it is to be removed from the terminal block 124, but before the redundant I / O component 122 is physically removed from the terminal block 124. In this way, the method 250 facilitates a seamless or disturbance-free transition of the redundant I / O components 122, 123 from a duplexed mode of operation to a separate duplexed mode of operation (e.g., by the redundant I / O component 123). While the following description of the method 250 is described in a particular order, it should be noted that the method 250 is not limited to the described order, and instead, the method 250 can be performed in any suitable order. Further, while some blocks of the method 250 are described as being performed by the redundant I / O component 122, it should be noted that these steps can be performed by the redundant I / O component 123 if the redundant I / O component 123 has one or more failed channels and / or is being removed from the terminal block 124. Similarly, while some blocks of the method 250 are described as being performed by the redundant I / O component 123, it should be noted that these steps can be performed by the redundant I / O component 122 if the redundant I / O component 123 has one or more failed channels and / or is being removed from the terminal block 124.

[0040] Referring now to Figure 4 At block 252, the redundant I / O component 122 with the failed channel 206 can receive a signal indicating that the redundant I / O component 122 is to be unlocked from the terminal block 124. In particular embodiments, a maintenance technician can move the actuator 218 associated with the redundant I / O component 122 from a locked position (e.g., the position of the actuator 219 in Figure 3 the terminal block 124) to an unlocked position (e.g., the position of the actuator 219 in Figure 3The sensor associated with the actuator 218 can send a signal to the redundant I / O component 122 indicating that the redundant I / O component 122 is unlocked from the terminal block 124. For example, the redundant I / O component 122 can include a sensor that detects the position of the actuator 218, the terminal block 124 can include a sensor that detects the position of the actuator 218, or both. Upon receiving the signal indicating that the redundant I / O component 122 is unlocked from the terminal block 124, at block 254, the redundant I / O component 122 can generate a schedule for completing the decoupling process that decouples the redundant I / O component 122 from the one or more terminals associated with the terminal block 124. For example, the redundant I / O component 122 can select a particular time or a particular time period to begin the decoupling process. The redundant I / O component 122 can then send or push the schedule for the decoupling process to the redundant I / O component 123 of the non-failed channel 206.

[0041] Upon receiving the schedule for the decoupling process, at block 256, the redundant I / O component 123 can determine whether the schedule for the decoupling process conflicts with its own schedule for performing one or more operations. For example, the redundant I / O component 123 can have one or more diagnostic operations scheduled to be performed at a particular time. If the redundant I / O component 123 determines that the schedule for the decoupling process does not conflict with its own schedule for performing one or more operations, at block 258, the redundant I / O component 123 can accept the received schedule for the decoupling process. For example, the redundant I / O component 123 can send a signal or message to the redundant I / O component 122 indicating acceptance. However, if the redundant I / O component 123 determines that the schedule for the decoupling process conflicts with its own schedule for performing one or more operations, at block 260, the redundant I / O component 123 can generate a new schedule for completing the decoupling process and send the new schedule to the redundant I / O component 122. At block 262, the redundant I / O component 122, upon receiving the new schedule from the redundant I / O component 123, can accept the new schedule. For example, the redundant I / O component 122 can send a signal or message to the redundant I / O component 123 indicating acceptance.

[0042] Upon the redundant I / O component 122 accepting the decoupling schedule at block 262, or upon the redundant I / O component 123 accepting the decoupling schedule at block 258, at block 264, the redundant I / O components 122, 123 can proceed to perform the decoupling process associated with the redundant I / O component 122 and the reconfiguration process associated with the redundant I / O component 123. That is, at the scheduled time, the redundant I / O component 122, which has been unlocked from the terminal block 124, can perform the decoupling process, while the redundant I / O component 123 can perform the reconfiguration process to switch each isolated channel of the redundant I / O component 123 from the duplexed mode of operation to the separate duplexed mode of operation.

[0043] In particular embodiments, the reconfiguration process associated with redundant I / O component 123 can be performed prior to the disengagement process associated with redundant I / O component 122. For example, after each isolated channel (e.g., 203) of redundant I / O component 122 is switched to a separate duplex mode of operation, redundant I / O component 123 can transmit state or configuration data associated with redundant I / O component 123 to redundant I / O component 122. In particular embodiments, the state or configuration data can include Highway Addressable Remote Transducer (HART) state data. Based on the received state or configuration data, redundant I / O component 122 can determine that redundant I / O component 123 has assumed control over the performance of any dedicated industrial automation input / output operations to facilitate communication with or control over I / O device 132. Redundant I / O component 122 can then disengage or decouple from one or more terminals associated with terminal block 124. After redundant I / O component 122 is disengaged from the terminals, redundant I / O component 122 can transmit state or configuration data associated with redundant I / O component 122 to redundant I / O component 123. In particular embodiments, the state or configuration data can include HART state data. Redundant I / O component 123 can utilize the state or configuration data to perform one or more dedicated industrial automation input / output operations.

[0044] After the disengagement process associated with redundant I / O component 122 and the reconfiguration process associated with redundant I / O component 123 are completed at block 264, redundant I / O component 122 can provide an indication that redundant I / O component 122 can be removed from terminal block 124. In particular embodiments, redundant I / O component 122 can display an indication that redundant I / O component 122 can be removed via a display screen or cause a light or any other suitable indicator associated with redundant I / O component 122 to indicate that redundant I / O component 122 can be removed. In any case, thereafter, a maintenance technician can remove redundant I / O component 122 from terminal block 124, leaving redundant I / O component 123 to operate in a separate duplex mode of operation.

[0045] As described above, a maintenance technician can replace redundant I / O component 122 with a replacement I / O component having a faulty channel 206. For example, the maintenance technician can insert the replacement I / O component into terminal block 124, pairing the replacement I / O component with redundant I / O component 123. In view of the above, redundant I / O component 123 can be configured to perform a reconfiguration process to facilitate the pairing of the replacement I / O component with redundant I / O component 123. In particular embodiments, the reconfiguration process can include redundant I / O component 123 transmitting state or configuration data associated with redundant I / O component 123 to the replacement I / O component. In particular embodiments, the state or configuration data can include HART state data. Based on the received state or configuration data, the replacement I / O component can determine that redundant I / O component 123 has assumed control over the performance of any dedicated industrial automation input / output operations to facilitate communication with or control over I / O device 132. The replacement I / O component can then disengage or decouple from one or more terminals associated with terminal block 124. After the replacement I / O component is disengaged from the terminals, the replacement I / O component can transmit state or configuration data associated with the replacement I / O component to redundant I / O component 123. In particular embodiments, the state or configuration data can include HART state data. Redundant I / O component 123 can utilize the state or configuration data to perform one or more dedicated industrial automation input / output operations. Figure 5is a block diagram 300 illustrating a reconfiguration process associated with the redundant I / O components 123 and a replacement I / O component 301 that has been plugged into the terminal block 124. As shown in block 300A of Figure 5 The redundant I / O components 123 operate in a separate duplex mode to perform one or more dedicated industrial automation input / output operations, as shown in block 300A of

[0046] After the replacement I / O component 301 has been plugged into the terminal block 124, the replacement I / O component 301 and the redundant I / O components 123 can perform a pairing process. For example, the replacement I / O component 301 and the redundant I / O components 123 can perform the pairing process after a maintenance technician has locked the replacement I / O component 301 in the terminal block 124. In particular embodiments, the maintenance technician can rotate the actuator 318 associated with the replacement I / O component 301 a quarter turn to lock or unlock the replacement I / O component 301 relative to the terminal block 124. However, it should be noted that in other embodiments, any other suitable locking mechanism can be used to secure the replacement I / O component 301 to the terminal block 124. Additional details regarding the pairing process performed by the replacement I / O component 301 and the redundant I / O components 123 will be described below with reference to Figure 6

[0047] After the replacement I / O component 301 and the redundant I / O components 123 have been paired, the replacement I / O component 301 and the redundant I / O components 123 can switch to a duplex mode of operation to coordinate performance of one or more dedicated industrial automation input / output operations. As shown in block 300B of Figure 5 Each isolated channel 302, 304, 306, 308, 310, 312, 314, 316 in the replacement I / O component 301 and each isolated channel 203, 205, 207, 209, 211, 213, 215, 217 in the redundant I / O components 123 operate in a duplex mode, as shown in block 300B of

[0048] ​In view of the above, Figure 6 A flowchart of a method 350 of pairing the replacement I / O component 301 with the redundant I / O component 123 after the replacement I / O component 301 has been inserted into the terminal block 124 is shown. While the description of the method 350 below is described as being in a particular order, it should be noted that the method 350 is not limited to the described order, and instead, the method 350 can be performed in any suitable order. Referring now to FIG. 35, the method 350 begins at block 352. Figure 6 At block 352, the replacement I / O component 301 can detect the presence of the redundant I / O component 123 and / or the redundant I / O component 123 can detect the presence of the replacement I / O component 301. In particular embodiments, the replacement I / O component 301 can broadcast a signal indicating the presence of the replacement I / O component 301 in the area around the replacement I / O component 301, the redundant I / O component 123 can broadcast a signal indicating the presence of the redundant I / O component 123 in the area around the redundant I / O component 123, or both. For example, each I / O component 123, 301 can broadcast the respective signal at a frequency greater than the scan rate of the I / O component 123, 301 or at any other suitable rate.

[0049] After the replacement I / O component 301 detects the redundant I / O component 123 and / or the redundant I / O component 123 detects the replacement I / O component 301 at block 352, the replacement I / O component 301 can verify hardware and software compatibility with the redundant I / O component 123 and / or the redundant I / O component 123 can verify hardware and software compatibility with the replacement I / O component 301. If the redundant I / O component 123 determines that the replacement I / O component 301 is hardware and / or software incompatible and / or the replacement I / O component 301 determines that the redundant I / O component 123 is hardware and / or software incompatible, the replacement I / O component 301 can provide an indication of the hardware and / or software incompatibility at block 356. For example, the replacement I / O component 301 can provide the indication through a display, LED, or the like.

[0050] However, if redundant I / O component 123 determines that replacement I / O component 301 is hardware and / or software compatible, and / or replacement I / O component 301 determines that redundant I / O component 123 is hardware and / or software compatible, at block 358, replacement I / O component 301 can receive a connection request from controller 12 (i.e., the connection initiator). For example, controller 12 can attempt to establish a connection with replacement I / O component 301 after receiving an indication (e.g., via backplane 128) that replacement I / O component 301 is present. For example, the indication can include an identifier of replacement I / O component 301, an indication of the hardware and / or software compatibility of replacement I / O component 301, or any other suitable information. The connection request sent by controller 12 to replacement I / O component 301 can include configuration information associated with replacement I / O component 301. For example, the configuration information can include an operating mode (e.g., simplex duplex mode or duplex mode) associated with replacement I / O component 301 and / or an identifier associated with a partner I / O component (e.g., redundant I / O component 123) of replacement I / O component 301.

[0051] Upon receiving the connection request from the controller 12, at block 360, the replacement I / O component 301 can determine whether the replacement I / O component 301 can accept connection to the controller 12 based on the received configuration information. For example, if the configuration information indicates a duplex operating mode and a partner I / O component has been detected (e.g., at block 352), the replacement I / O component 301 can accept connection to the controller 12 after verifying with the partner I / O component (e.g., redundant I / O component 123) that the duplex configuration is correct and matches the configuration of the partner I / O component, determining whether the replacement I / O component 301 is the primary or secondary component in a pair of potentially redundant I / O components, performing time synchronization with the partner I / O component, or a combination thereof. Alternatively, if the configuration information indicates a duplex operating mode but no partner I / O component has been detected (e.g., at block 352), the replacement I / O component 301 can accept connection to the controller 12 after verifying that the duplex operating mode is the correct configuration for the replacement I / O component 301. For example, the replacement I / O component 301 can send a request to the controller 12 to confirm the setting of the duplex operating mode. If the controller 12 confirms that the setting of the duplex operating mode is valid, the replacement I / O component 301 can accept connection to the controller 12. If the controller 12 does not confirm that the setting of the duplex operating mode is valid, the replacement I / O component 301 can not accept connection to the controller 12 and can enter a "standby" or "rest" mode (e.g., at block 362). Alternatively, if (1) the configuration information indicates a duplex configuration and a partner I / O component (e.g., redundant I / O component 123) is identified as having incompatible hardware and / or software configurations, or (2) the configuration information indicates a single duplex configuration, the replacement I / O component 301 can accept connection to the controller after verifying that there are no conflicts with adjacent I / O components, verifying that the single duplex configuration is valid, or both. However, if one or more of the above-described conditions for accepting connection to the controller 12 are not met, the replacement I / O component 301 can not accept connection to the controller 12 and can enter a "standby" or "rest" mode (e.g., at block 362).

[0052] Upon accepting the connection to the controller 12, at block 364, if the configuration information associated with the replacement I / O component 301 indicates a duplex mode of operation, the replacement I / O component 301 can proceed to pair with a partner I / O component (e.g., the redundant I / O component 123). In particular, the replacement I / O component 301 and the redundant I / O component 123 can negotiate a suitable time for each pair of isolation channels between the replacement I / O component 301 and the redundant I / O component 123 to switch to the duplex mode of operation. In a particular embodiment, the replacement I / O component 301 can generate a schedule defining a particular time or a particular time period for performing the pairing process between the replacement I / O component 301 and the redundant I / O component 123, and send the schedule to the redundant I / O component 123. Upon receiving the schedule from the replacement I / O component 301, the redundant I / O component 123 can determine whether the schedule for the pairing process conflicts with its own schedule for performing one or more operations. If the redundant I / O component 123 determines that the schedule for the pairing process does not conflict with its own schedule for performing one or more operations, the redundant I / O component 123 can accept the received schedule for the pairing process. For example, the redundant I / O component 123 can send a signal or a message to the replacement I / O component 301 indicating the acceptance. However, if the redundant I / O component 123 determines that the pairing process conflicts with its own schedule for performing one or more operations, the redundant I / O component 123 can generate a new schedule for completing the pairing process, and send the new schedule to the replacement I / O component 301. Upon receiving the new schedule from the redundant I / O component 123, the replacement I / O component 301 can accept the new schedule. For example, the replacement I / O component 301 can send a signal or a message to the redundant I / O component 123 indicating the acceptance.

[0053] Upon the redundant I / O component 123 or the replacement I / O component 301 accepting the pairing schedule, the redundant I / O component 123, 301 pair can proceed to perform the pairing process at the scheduled time. That is, at the scheduled time, the replacement I / O component 301 can connect or couple to one or more terminals associated with the terminal block 124. Further, each pair of isolation channels between the redundant I / O component 123 and the replacement I / O component 301 can switch to the duplex mode of operation such that each pair of isolation channels can coordinate the performance of dedicated industrial automation input / output operations to facilitate the communication of or control over the I / O devices 132 by the controller 12.

[0054] The technologies proposed and claimed herein are referenced to and applied to specific examples that significantly improve the physical and practical aspects of the prior art; therefore, these technologies are not abstract, intangible, or purely theoretical. Furthermore, if any claim appended to this specification contains one or more elements designated as "means for [performing] [the function]" or "steps for [performing] [the function]," it is intended that these elements be interpreted in accordance with 35U.SC112(f). However, for any claim containing elements designated in any other manner, it is intended that these elements not be interpreted in accordance with 35U.SC112(f).

[0055] While only some features of this disclosure have been described herein, many modifications and alterations can 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 consistent with the true spirit of this disclosure.

Claims

1. An I / O system of an industrial automation system, comprising: a terminal block comprising a plurality of terminals configured to be coupled to respective redundant I / O components; a first redundant I / O component removably coupled to a set of terminals of the plurality of terminals; and a second redundant I / O component removably coupled to the set of terminals of the plurality of terminals, wherein the first redundant I / O component and the second redundant I / O component are configured to operate in a duplex mode of operation; wherein the first redundant I / O component is configured to perform a first set of operations comprising: receiving a signal indicating that the first redundant I / O component is unlocked from the terminal block; generating a plan for disengaging the first redundant I / O component from the terminal block; sending the plan to the second redundant I / O component; receiving a new plan from the second redundant I / O component; and disengaging from the set of terminals based on the new plan; and wherein the second redundant I / O component is configured to perform a second set of operations comprising: receiving the plan from the first redundant I / O component; determining that the plan conflicts with one or more operations associated with the second redundant I / O component; generating the new plan for disengaging the first redundant I / O component from the terminal block; and sending the new plan to the first redundant I / O component; and reconfiguring the second redundant I / O component to operate in a single duplex mode of operation. The first redundant I / O component comprises a first set of isolation channels and the second redundant I / O component comprises a second set of isolation channels.

2. The I / O system of claim 1, wherein, 3. The I / O system of claim 1, comprising an actuator configured to lock or unlock the first redundant I / O component relative to the terminal block. The actuator is configured to be disposed in a locked position or an unlocked position.

4. The I / O system of claim 3, comprising a sensor configured to detect a position of the actuator, wherein, The signal indicating that the first redundant I / O component is unlocked from the terminal block is received from the sensor.

5. The I / O system of claim 4, wherein, 6. A method for an I / O system of an industrial automation system, comprising: receiving, by a first redundant I / O component removably coupled to a set of terminals of a plurality of terminals of a terminal block, a signal indicating that the first redundant I / O component is unlocked from the terminal block; generating, by the first redundant I / O component, a plan for disengaging the first redundant I / O component from the terminal block; sending, by the first redundant I / O component, the plan to a second redundant I / O component removably coupled to the set of terminals of the plurality of terminals of the terminal block; receiving, by the second redundant I / O component, the plan from the first redundant I / O component; determining, by the second redundant I / O component, that the plan conflicts with one or more operations associated with the second redundant I / O component; generating, by the second redundant I / O component, a new plan for disengaging the first redundant I / O component from the terminal block; sending, by the second redundant I / O component, the new plan to the first redundant I / O component; ​ receiving, by the first redundant I / O component, the new schedule from the second redundant I / O component; disengaging, by the first redundant I / O component, from the terminal set associated with the terminal block based on the new schedule; and reconfiguring, by the second redundant I / O component, an operating configuration associated with the second redundant I / O component into a separate duplex operating mode based on the new schedule.

7. The method of claim 6, wherein, reconfiguring the operating configuration associated with the second redundant I / O component from a duplex operating mode into the separate duplex operating mode.

8. The method of claim 6, wherein, a fault occurred in an isolation channel of the first redundant I / O component prior to the first redundant I / O component receiving the signal indicating that the first redundant I / O component is unlocked from the terminal block.

9. The method of claim 6, comprising: detecting, by the second redundant I / O component, a third redundant I / O component removably coupled to the terminal block.

10. The method of claim 9, comprising: determining, by the second redundant I / O component, that a first hardware configuration, a first software configuration, or both, associated with the second redundant I / O component is compatible with a second hardware configuration, a second software configuration, or both, associated with the third redundant I / O component.

11. The method of claim 10, reconfiguring, by the second redundant I / O component, the operating configuration into a duplex operating mode, and reconfiguring, by the third redundant I / O component, a second operating configuration associated with the third redundant I / O component into the duplex operating mode.

12. A non-transitory computer-readable medium comprising computer-executable instructions that, when executed by one or more first processors associated with a first redundant I / O component in an industrial automation system and one or more second processors associated with a second redundant I / O component in the industrial automation system, cause the one or more first processors and the one or more second processors to perform operations of the method of any of claims 6-11.

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