Carrier module device for retrofit in a control cabinet and assembly method thereof

Abstract

The present disclosure relates to a carrier module device for retrofitting in a control cabinet and an assembly method thereof. A carrier module assembly has a module removably attached to a carrier frame and a carrier riser. The carrier module assembly is capable of being inserted into a slot of a control cabinet without having to rewire or reconfigure the control cabinet. The length of the carrier module assembly enables the carrier module assembly to be located within the slot of the control cabinet. The module is removable from the carrier frame such that the module can be attached to a backplane of a rack.

Description

Technical Field

[0001] This disclosure generally relates to a carrier module device and the modification of a system including the carrier module device, and more specifically to a carrier module device and a method for modifying the carrier module device into an existing control cabinet. Background Technology

[0002] System controllers are frequently used to monitor the operation of machines and systems. A system controller can consist of a combination of modules, such as controller devices and I / O devices, arranged together in a mounting unit or slot, which is then supported in an enclosure or cabinet for field use. Systems and machines include field devices that monitor the operation of associated systems / machines. For example, field devices may include temperature and pressure transmitters. Signal cabling connects the field devices to the controller devices and I / O devices of the system controller.

[0003] During operation, the system controller periodically receives signals from field devices sent to the I / O devices of the installation unit. The I / O devices then forward the received signals to one of the controller devices included in the associated installation unit, and the controller device processes the I / O device signals. The system controller then sends signals to the field devices to initiate the required field device control actions.

[0004] System controllers can be installed for use in remote field locations. The performance of the mounting units degrades over time, necessitating periodic servicing or replacement. Because system controllers are located in remote locations, such as those often referred to as 'brownfield locations,' it is desirable to streamline the servicing and replacement process, for example, by limiting the number of potentially replaceable parts in the controller system. As an example of current servicing complexity, a typical mounting unit contains ten I / O devices, each with sixteen channels and two wires per channel, creating a total of 320 connection points. A typical controller cabinet contains eight typical mounting units, totaling 2560 individual wiring connections. Re-terminating these connections is an expensive and time-consuming operation. Furthermore, when new I / O devices and controller equipment are installed, they often cannot be reconnected to the existing signal cabling. Therefore, replacement signal cables compatible with the new components need to be installed. The new cabling requires verification that each wire is correctly connected. This complex servicing requirement necessitates shutting down the system associated with the controller when it is being serviced.

[0005] Therefore, there is a need to simplify the repair and replacement of controller devices and I / O devices in controller systems. More specifically, there is a need to repair or replace existing controller devices and I / O devices using modular components that are compatible with and can be coupled to existing signal wiring. Summary of the Invention

[0006] In one aspect, a carrier module assembly is disclosed. The carrier module includes a module having an interface, a rear plug, and sidewalls, and a carrier frame having a receptacle adapter. The receptacle adapter has a first side and a second side, the first side being configured to receive the rear plug of the module. The carrier module assembly also includes a carrier stand having a front bus connector configured to intersect with the second side of the receptacle adapter, and one or more of a bus port and a second bus connector.

[0007] In another aspect, a control cabinet is disclosed. The control cabinet includes: a back panel having an opening defining a plurality of slots; at least one of a controller device or I / O device, disposed in a first slot of the plurality of slots; and at least one carrier module assembly, disposed in a second slot of the plurality of slots. The at least one carrier module assembly includes: a module having an interface, a rear plug, and sidewalls; a carrier frame having a socket adapter having a first side and a second side, the first side being configured to receive the plug of the module; and a carrier stand having a front bus connector configured to intersect with the second side of the socket adapter, and one or more of a bus port and a bus connector.

[0008] In another aspect, a method for retrofitting a carrier module assembly into a control cabinet is disclosed. The method includes the steps of: removing a legacy device from a first slot in the control cabinet, the legacy device being connected to the back panel of the control cabinet; and inserting the carrier module assembly into the first slot. The controller assembly includes: a module having an interface, a plug, and a surface; a carrier frame having a receptacle adapter having a first side and a second side, the first side being configured to receive the plug of the module; and a carrier stand having a front bus connector configured to intersect with the second side of the receptacle adapter, and one or more of a bus port and a bus connector. The method also includes the step of reconnecting a pin connector to the bus connector of the carrier stand of the carrier module assembly. Attached Figure Description

[0009] The subject matter of the present invention will be explained in more detail below with reference to exemplary embodiments illustrated in the accompanying drawings.

[0010] Figure 1 The illustration shows a perspective view of a module according to one or more embodiments of the present disclosure.

[0011] Figure 2 The diagram shows Figure 1 A 3D view of the module.

[0012] Figure 3 The diagram shows Figure 1 A 3D view of the module.

[0013] Figure 4 The diagram shows Figure 1 The left-side view of the module.

[0014] Figure 5 The diagram shows Figure 1 The top view of the module.

[0015] Figure 6 The illustration shows a perspective view of a carrier module assembly according to one or more embodiments of the present disclosure.

[0016] Figure 7 The diagram shows Figure 6 An exploded view of the carrier module components.

[0017] Figure 8 The diagram shows Figure 6 A three-dimensional view of the carrier module components.

[0018] Figure 9 The diagram illustrates along Figure 6 The line A-A' intercepts Figure 6 A cross-sectional view of the carrier module component.

[0019] Figure 10 The diagram shows Figure 6 A three-dimensional view of the carrier module components.

[0020] Figure 11 The diagram shows Figure 6 A side view of the carrier module component.

[0021] Figure 12 The diagram illustrates the assembly process. Figure 6 The flowchart shows the method for using the carrier module component.

[0022] Figure 13 The illustration shows a perspective view of a control cabinet according to one or more embodiments of the present disclosure, the control cabinet having conventional equipment arranged in a slot within the control cabinet;

[0023] Figure 14 The diagram shows Figure 13 A perspective view of the control cabinet, which has two slots occupied by conventional equipment;

[0024] Figure 15 The diagram shows Figure 14 A three-dimensional view of the control cabinet, in which Figure 6 The carrier module component is installed Figure 14 In the two unused slots.

[0025] Figure 16 The diagram shows Figure 15 A three-dimensional view of the control cabinet, in which traditional equipment has been removed from the control cabinet.

[0026] Figure 17 The diagram shows Figure 13Rear perspective view of the control cabinet.

[0027] Figure 18 The diagram shows Figure 16 A top view of the control cabinet.

[0028] Figure 19 The illustration shows the modification using the carrier module component disclosed herein. Figure 16 The flowchart shows the method for controlling the cabinet.

[0029] Figure 20 The illustration shows a perspective view of a carrier module assembly according to one or more embodiments of the present disclosure.

[0030] Figure 21 The diagram shows Figure 20 A three-dimensional view of the carrier module components.

[0031] Figure 22 The diagram shows Figure 20 A three-dimensional view of the outer shell of the carrier module component.

[0032] Figure 23 The diagram shows Figure 20 A three-dimensional view of the bottom of the carrier module component shell.

[0033] Figure 24 The diagram shows Figure 20 A three-dimensional view of the socket adapter and bus connection of the carrier module component.

[0034] Figure 25 The diagram shows Figure 24 An exploded view of the socket adapter and bus connection of the carrier module component.

[0035] Figure 26 The illustration shows a perspective view of a track according to one or more embodiments of the present disclosure; and,

[0036] Figure 27 The diagram shows the installation to Figure 26 A three-dimensional view of the carrier module on the track.

[0037] The reference symbols used in the accompanying drawings and their meanings are listed in summary form in the reference symbol list. In principle, the same parts are provided with the same reference symbols in the accompanying drawings. Detailed Implementation

[0038] In the following specification and claims, reference will be made to a number of terms which should be defined to have the following meanings.

[0039] As used herein, the singular forms “a,” “an,” and “the” include plural indicators unless the context clearly specifies otherwise. The terms “comprising,” “including,” and “having” are intended to be inclusive and indicate that additional elements other than those listed may be present. The terms “optional” or “optionally” mean that an event or situation subsequently described may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0040] As used herein, the terms “PCB” or “printed circuit board” as used in this disclosure shall refer to the sub-state in which electronic components are mounted and the conductive paths or traces arranged on a substrate connect the electronic components.

[0041] As used herein, the terms "traditional" and "existing" refer to equipment that has been installed in a commercial or industrial application. Traditional or existing equipment may remain functional or may require replacement. Traditional or existing equipment is compatible with the modules disclosed herein.

[0042] As used herein, the terms “connector,” “bus connector,” “bus port,” “contact,” and “plug” refer to electrical contacts configured to transmit data or provide low-voltage power to a module or device or this disclosure. A contact may be a plated finger-shaped contact on the edge of a printed circuit board, which may intersect with the support connectors of different components. A contact may also be a MOBUS pin connector. Each plated finger or pin may correspond to one bit. By way of example, a connector with 16 fingers or pins may correspond to a 16-bit data transfer connection between components.

[0043] Embodiments of this disclosure relate to a carrier module assembly. The carrier module assembly includes a carrier frame and a carrier stand. Modules may vary in size and form factor, requiring rewiring and installation time when installed in conventional control cabinets. The carrier module assembly is configured to receive modules, allowing modules to be assembled into conventional control cabinets without rewiring or otherwise modifying the carrier module assembly or control cabinet. Therefore, the carrier module assembly of this disclosure is used to retrofit modules into control cabinets and control systems. The module can be removed from the carrier module assembly, allowing it to be reused in slotted control cabinets and racks for direct reception.

[0044] Now, especially referencing Figures 1 to 5Module 100 includes a two-piece plastic housing 102 that encloses at least one printed circuit board (PCB) (not shown). The two-piece plastic housing 102 is rectangular in shape. The PCB includes a microprocessor, memory, and other circuitry. The memory stores a control program executed by the microprocessor. The control program may include one or more control loops, such as a PID loop, that operate on one or more field inputs to generate a control output. In some embodiments, one piece of the two-piece plastic housing 102 includes a passive cooling element 116. In some embodiments, the passive cooling element 116 includes a slot opening that allows passive airflow to pass through and surround the PCB, thereby cooling the printed circuit board and associated PCB components. See also Figure 1 and 5 In some embodiments, the passive cooling element 116 includes an aluminum heat sink or more generally a metal heat sink, which is connected to the PCB to conduct heat from the PCB and thus dissipate heat from the PCB.

[0045] A cylindrical base 106 typically extends from the side wall 104 of the housing 102. For example... Figure 2 and 3 As best shown in the diagram, the cylindrical base 106 includes a hole 107 extending axially through the base 106. In some embodiments, the base 106 is located on a sidewall opposite the cooling element 116. As explained in further detail below, fasteners may be inserted into the hole in the base 106 for connecting the module 100 to other components of this disclosure.

[0046] like Figure 1 As best shown, housing 102 includes an interface 110 along the front portion of the housing. In some embodiments, interface 110 includes one or more of a connection port 112 and a status indicator 114. In some embodiments, connection port 112 is a serial connection port, an Ethernet connection port, a USB port, or a fiber optic connection port. In some embodiments, status indicator 114 corresponds to one or more channels, connections, or processes performed by module 100.

[0047] like Figure 2 As shown, housing 102 defines a rear connector 108 arranged along a PCB enclosed by housing 102. The rear connector 108 is adapted to receive a mating connection member that may be included along a mating PCB (not shown). The rear connector 108 is configured as a MOBUS connector, or more generally, a data communication protocol, for use with a programmable logic controller. The rear connector 108 and the mating PCB are engaged in a conventional manner.

[0048] When the module is installed for use, the circuitry on the PCB processes field inputs received from field sensors or control outputs received from one or more I / O or controller devices, depending on whether module 100 is programmed to monitor and process inputs or outputs, or whether module 100 is an I / O module or a controller device. More specifically, the circuitry converts analog signals (e.g., analog 4 to 20 mA, digital 24 VDC, etc.) received from devices installed at the location / field of interest using conventional analog-to-digital and / or digital-to-analog converters, converts analog signals to digital controller signals, and also converts digital signals back to analog signals. The circuitry also regulates signals received from or sent to the field by effectively using switches, filters, and multiplexers. Therefore, the desired signal is isolated from multiple field signals received and sent by one or more I / O or controller devices.

[0049] like Figures 6 to 9 As shown, the carrier module assembly 200 includes a carrier frame 210, a carrier stand plate 250, and a module 100 attached to the carrier frame. The carrier frame 210 and the carrier stand plate 250 define the carrier sub-assembly 202.

[0050] The carrier frame 210 includes an elongated body having a first end 218 and a second end 220 (e.g., defining a length L1) of a certain length L1. Figure 11 (As shown). The first end 218 includes at least one hole 222 configured to receive fasteners for securing the front panel 280 to the carrier frame 210, as explained in further detail below. In some embodiments, the second end 220 includes a protrusion 226 extending from a surface 224 of an elongated body. In some embodiments, the protrusion 226 is located at a distance from the second end 220 of the carrier frame. A receptacle adapter 212 is disposed on the protrusion 226 to connect the rear connector 108 to a first bus connector 252 of the carrier stand 250. In some embodiments, a set of pins 230 protrudes from the surface 224. The receptacle adapter 212, the carrier frame 210, and the first bus connector 252 of the carrier stand 250 are configured as MOBUS connectors or, more generally, data communication protocols for use with a programmable logic controller.

[0051] like Figure 8 and 9As shown, in some embodiments, a set of apertures 232 is provided along the surface 224 of the carrier frame 210. A set of pins 230 of the carrier frame 210 is configured to intersect with a first corresponding aperture 258 of the carrier stand 250 when the carrier frame 10 is placed above the carrier stand 250. In some embodiments, the set of apertures 232 of the carrier frame 210 is configured to receive pins (not shown) in the carrier frame 210 to form a snap-fit ​​connection. In some embodiments, the set of apertures 232 is aligned with a corresponding second set of apertures 260 such that fasteners can be inserted through the carrier frame 210 and the carrier stand 250 to reversibly connect the carrier frame 210 and the carrier stand 250.

[0052] like Figure 8 As best illustrated, in some embodiments, surface 224 includes a cylindrical base 228 for mechanically securing module 100 and carrier frame 210. When the module is secured to the carrier frame, sidewall 104 of module 100 is positioned near surface 224 of carrier frame 210 such that the cylindrical base 106 of module 100 and the cylindrical base 228 of carrier frame are aligned to allow fasteners to be inserted through holes 107. Fasteners are threadedly connected to the cylindrical base 106 of module 100 and the cylindrical base 228 of carrier frame 210 to removably secure module 100 to carrier frame 210. In some embodiments, module 100 is secured to carrier frame 210 by other fastening means, such as snap-fit ​​assembly or adhesive used between module 100 and carrier frame 210.

[0053] Reference Figures 6 to 9 The carrier plate 250 includes an elongated body having a first end 262 and a second end 264 (e.g., defining a length L2) of L2. Figure 11 (As shown). The carrier stand 250 includes a first bus connector 252 configured to intersect with a second side 216 of the socket adapter 212 of the carrier frame 210. In some embodiments, the carrier stand 250 also includes a bus port 254 extending from a second end 264. In some embodiments, the carrier stand 250 also includes a second bus connector 256 extending from the second end 264. In some embodiments, the bus port 254 is configured to supply power or current to the module 100. As explained in further detail below, the bus port 254 of the carrier stand 250 is configured to intersect with a bus port 362 of the back panel 340 of the control cabinet 300, as shown. Figure 16As shown. In some embodiments, the carrier stand 250 is a PCB configured to transmit electrical and data signals from a first bus connector 252 to a second bus connector 256 and a bus port 254. In some embodiments, the carrier stand 250 includes a body having electrical traces or paths configured to transmit electrical and data signals from the first bus connector 252 to the second bus connector 256 and the bus port 254.

[0054] In some embodiments, the second bus connector 256 is a MOBUS connector or, more generally, a data communication protocol for use with a programmable logic controller. The second bus connector 256 is configured to connect to the pin connector 304 of the process socket adapter 360 or cable 302 (e.g., Figure 7 , 14 (As shown in Figure 17). Figure 7 and 17 As shown, the process socket adapter 360 includes a first end with a bus connector 362 and a second end with a PLC connector or system connector (such as MOBUS, Ethernet, digital, analog connector).

[0055] Reference Figure 7 , 10 11. The front panel 280 is removably attached to the carrier frame 210. The front panel 280 includes a body having a first end 282 and a second end 284. The width W1 of the front panel 280 is greater than the width W2 of the carrier frame 210, such that the front panel 280 protrudes beyond either side of the carrier frame 210. The front panel 280 also includes a first set of threaded bores (not shown) that partially extend into the second end 284, at which point the front panel 280 protrudes beyond the carrier frame 210. Each threaded bore in the first set of threaded bores is configured to align with at least one hole 222 in the carrier frame 210, such that the front panel 280 can be removably attached to the carrier frame 210.

[0056] Module 100, carrier frame 210, and carrier stand 250 are removably connected to each other to form carrier module assembly 200. Module 100 can be separated from the carrier sub-assembly 202 defined by carrier frame 210 and carrier stand 250. Carrier module assembly 200 is sized to fit into slot 320 of control cabinet 300. The ability to appropriately size the carrier module assembly for fitting into existing control cabinet configurations enables efficient and effective replacement of conventional I / O devices and controller devices. Figure 11 As shown, the carrier module assembly 200 has a total length L3 defined by the length L1 of the carrier frame 210 and the length L2 of the carrier stand plate 250. For the module 100 of this disclosure, the length L1 of the carrier frame 210 is substantially equal to the length of the module 100.

[0057] Carrier stand plates of different lengths L2 can be used to replace carrier stand plates 250, allowing for the retrofitting of carrier module assembly 200 in control cabinets of varying lengths. For example, while most control cabinets have a standard slot length of approximately 12 inches (30.48 cm), the length of a control cabinet can range from 10 to 18 inches. Therefore, any suitable length of carrier stand plate 250 can mate with carrier frame 210, allowing carrier module assembly 200 to be assembled, installed, or retrofitted into units with slot lengths of 10 to 18 inches (25.4 cm to 45.72 cm). In other words, carrier module assembly 200 can have a total length LT of 10 to 18 inches, and shorter or longer carrier stand plates 250 can be used to mount module 100 into conventional control cabinets for the purpose of this disclosure. As explained in further detail below, module 100 can be removed from carrier module assembly 200 and installed in other cabinets or racks.

[0058] like Figure 12 As shown, a method 400 for assembling a carrier module assembly 200 includes: inserting a second side 216 of a socket adapter 212 of a carrier frame 210 into a first bus connector 252 of a carrier stand 250; inserting a rear connector 108 of the module into a first side 214 of the socket adapter 212 of the carrier frame 210; and connecting a front panel 280 to the carrier frame 210. In some embodiments, the method further includes attaching a module 100 to the carrier frame 210. In some embodiments, the method further includes inserting a bus port 254 of the carrier stand 250 into a port 356 of a back panel 340 of a control cabinet 300. In some embodiments, the method further includes inserting the carrier module assembly 200 into a slot 320 of the control cabinet 300.

[0059] Figure 13 The illustration shows a control cabinet 300, in which a row of conventional / existing equipment 50 is arranged side-by-side in multiple associated slots 320. Figure 13 In the text, many similar exemplary slots are identified as 320a, 320b, and 320c. Figure 14 The illustration shows a control cabinet 300 with two empty slots 320a and 320b out of a plurality of slots 320. Figures 15 to 18 The illustration shows the installation or modification to Figure 14The carrier module assembly 200 of this disclosure is located in two empty slots 320a and 320b of control cabinet 300. Extended field use of legacy equipment 50 leads to operational degradation of the legacy equipment over time. The functional degradation of existing control cabinets 300 necessitates frequent maintenance or replacement. The module 100 disclosed herein can be used to replace / repair known legacy equipment 50; however, module 100 cannot be installed in existing control cabinets 300 without significant rewiring, modification, or replacement of the entire control cabinet 300 because module 100 is smaller than legacy equipment 50. The carrier module assembly 200 of this disclosure allows module 100 to be located in an existing cabinet without requiring rewiring or modification of the control cabinet 300.

[0060] As previously described, the total length L3 of the carrier module assembly 200 is defined by the length L1 of the carrier frame 210 and the length L2 of the carrier stand 250. The length of the module 100 is substantially the same as the length of the carrier frame 210. The total length L3 is adapted to allow the carrier module assembly to be located in the control cabinet without rewiring or other typical modifications. The total length of the carrier assembly L3 is substantially the same as the length of the cabinet L4, as described in detail below, and allows the assembly to be received in the cabinet slot. Depending on the size of the control cabinet 300, as the cabinet length L4 varies, a carrier stand 250 with a suitable length L2 can be provided such that the length L3 is aligned with the control cabinet length L4.

[0061] like Figure 13 , Figure 14 and Figures 17-18 As shown, the field control cabinet 300 supports multiple installed conventional devices 50. The control cabinet 300 has a housing defined by a back panel 340, side panels 310, a top panel 312, and a bottom panel 314. The ends of the back panel 340, top panel 312, and bottom panel 314 are conventionally supported at the plate ends by the side panels 310. Each of the top panel 312 and bottom panel 314 includes a plurality of forward-oriented holes 306a and 306b. The holes 306a and 306b extend along the top and bottom panels between the side panels 310. Figure 14 As shown, paired horizontally aligned top holes 306a and bottom holes 306b are located above and below the entry openings of the corresponding slots 320. Slots 320 extend from the front end 316 to the back panel 340 and have a length L4, which also defines the length of the cabinet. Adjacent conventional devices 50 can be connected in series via bridges 52 to increase switching power. Figure 17 and 18As shown, conventional device 50 is connected to pin connector 304 or process socket adapter 360. Conventional device 50 is secured by fastening the conventional device to a pair of aligned holes 306a, 306b. Similarly, front panel 280 also includes a second set of apertures (not shown) extending through a first end 282 and a second end 284. The second set of apertures is configured to align with holes 306 of control cabinet 300. The second set of apertures can be threaded onto or otherwise secured to cabinet 300 by fasteners 288. The first and second sets of apertures are arranged on a protrusion of front panel 280. Front panel 280 also includes an opening 290 extending through the body, such that when module 100 is attached to carrier frame 210, the opening provides access to interface 110 of module 100. In some embodiments, front panel 280 abuts interface 110 of module 100.

[0062] like Figure 14 As shown, one or more legacy devices 50 can be removed and replaced from slot 320 of control cabinet 300. The legacy device 50 is removed without requiring removal or rewiring of the pin connector 304 or process socket adapter 360. (As shown...) Figure 15 As shown, the carrier module assembly 200 can be installed to typically replace the conventional controller, and specifically, for illustrative purposes, is installed into empty slots 320a and 320b of the plurality of slots 320. Figure 15 , Figure 17 and Figure 18 As shown, since the total length L3 of the carrier module assembly 200 is equal to the length L4 of the slot 320, the carrier module assembly 200 is installed without removing or rewiring the pin connector 304 or the process socket adapter 360.

[0063] like Figure 16 and Figure 17As shown, each slot 320 includes a track 322 disposed on a top plate 312 (not shown) and a bottom plate 314. The track 322 extends at least partially along the length L4 of the slot 320 and is configured to intersect with the side edges 266 of the carrier stand 250. By orienting the carrier module assembly 200 when it is inserted into the slot 320 until the assembly end 264 is near the back plate 340, the track 322 ensures that the carrier module assembly 200 is correctly positioned in the slot 320. In some embodiments, the back plate 340 is a PCB. In some embodiments, the back plate 340 is a PCB having a metal backplate for rigidity and support. The back plate 340 includes a bus port 362 for each slot 320, and the bus ports 362 are configured to intersect with the bus ports 254 of the carrier stand 250 to provide power to the module 100. The backplate 340 also includes an opening 364 through which at least part of the second bus connector 256 of the carrier stand passes, such that the second bus connector 256 can be connected to one of the pin connectors 304 of the process socket adapter 360 or the cable 302, as shown. Figure 17 As shown. Figure 16 As shown, the carrier module assembly 200 can be removably secured to the control cabinet 300 by fasteners 288, which are received by holes 306 and tightened against the top and bottom plates to the front plate.

[0064] Therefore, legacy device 50, which may be an I / O device or a controller device, can be removed from control cabinet 300, and carrier module assembly 200 can be inserted into empty slot 320. The newly installed carrier module assembly 200 can communicate and operate with the existing legacy device 50, which is installed and operates with control cabinet 300. Therefore, replacement of the entire control cabinet 300 is unnecessary, as only the individual legacy device 50 needs to be replaced by carrier module assembly 200 as needed. Carrier module assembly 200 can be installed to replace defective legacy device 50 or to upgrade control cabinet 300 with additional features of module 100. Because carrier stand 250 can have any length L2, carrier module assembly 200 can be installed in a standard control cabinet 300 with a slot length L4 of 12 inches (30.48 cm), or in a non-standard control cabinet with a slot length L4 of 10 inches to 18 inches (25.4 cm to 45.72 cm).

[0065] like Figure 19 As shown, a method 500 for retrofitting a carrier module assembly 200 to a control cabinet 300 includes: removing 502 one or more conventional devices 50 from a first slot 320 of a plurality of slots 320 in the control cabinet 300, one or more of the conventional devices 50 being connected to a back panel 340 of the control cabinet 300; inserting 504 the carrier module assembly 200 into the first slot 320. Figure 16 The method 500 includes a pin connector 304 reconnected 506 to a second bus connector 256 of a carrier stand plate 250 of a carrier module assembly 200, in one of two empty slots 320a and 320b; and a second bus connector 256 for reconnecting the pin connector 304 to the carrier stand plate 250 of the carrier module assembly 200. In some embodiments, the method 500 further includes removably securing 508 the front plate 280 to holes 306 in each slot 320 of the control cabinet 300.

[0066] Carrier module assembly 200 and module 100 can be installed in the field and retrofitted into control cabinet 300. Module 100 is capable of communicating and integrating with general-purpose controller systems. Because module 100 is removable from carrier module assembly 200, module 100 can be removed from carrier subassembly 202, and module 100 can be reused and installed into... Figure 27 The controller rack 700 is described in further detail below.

[0067] like Figures 20 to 27 As shown, module 100 can be removed from carrier module subassembly 202 and can be installed into rack 700 using carrier module assembly 600. Rack 700 does not include side panels and associated cabinet length, therefore the length of carrier module assembly 600 is less than the length L3 of carrier module assembly 200. More specifically, carrier module assembly 600 includes module 100, carrier frame 610, carrier upright 650, and housing 604 surrounding carrier frame 610 and carrier upright 650. Carrier frame 610, carrier upright 650, and housing 604 define carrier subassembly 602.

[0068] Reference Figures 22 to 25 The carrier frame 610 includes a body 611 having a first surface 618 and a second surface 620. A receptacle adapter 612 is disposed on the body to connect a rear connector 108 to a first bus connector 652 of the carrier stand 250. The receptacle adapter 612, the carrier frame 610, and the first bus connector 652 of the carrier stand 650 are configured as a MOBUS connector or, more generally, a data communication protocol for use with a programmable logic controller. The carrier stand 650 includes an elongated body having a first end 662 and a second end 664. The carrier stand 650 includes a first bus connector 652 configured to intersect with a second side 616 of the receptacle adapter 612 of the carrier frame 610. In some embodiments, the carrier stand 250 also includes a bus port 654 extending from the second end 664. In some embodiments, the bus port 654 is configured to provide power or current to the module 100. Figure 26 As shown, the bus port 654 of the carrier stand plate 650 is configured to intersect with the bus port 762 of the back plate 740 of the rack 700.

[0069] In some embodiments, the second bus connector 656 is a MOBUS connector or, more generally, a data communication protocol for use with a programmable logic controller. The second bus connector 656 is configured to connect to the pin connector 304 of the process socket adapter 360 or cable 302 (e.g., ...). Figure 17 and 27 (As shown).

[0070] like Figure 21 and 22 As best shown, housing 604 includes a hollow body having a first surface 670 and an open second surface 672. The first surface 670 includes an opening 674 such that the receptacle adapter 612 of carrier frame 610 can receive the rear connector 108 of module 100. The open second surface 672 is generally hollow, exposing bus port 654 and a second bus connector 656, which can be connected to the pin connector 304 of process receptacle adapter 360 or cable 302 when carrier module assembly 600 is mounted to backplane 740. Figure 26 As shown.

[0071] The first surface 670 of the housing 604 includes a protrusion 676 extending from one side of the first surface 670. The protrusion 676 includes an inward surface 678 having a cylindrical base 680 for mechanically securing the module 100 to the housing 604. When the module 100 is attached to the carrier frame 610, the cylindrical base 106 of the module 100 is aligned with the cylindrical base 680 of the housing 604. Fasteners can then be threaded through the cylindrical base 106 of the module 100 and the cylindrical base 680 of the housing 604 to removably attach the module 100 to the housing 604.

[0072] like Figure 26 and 27 As shown, the carrier module assembly 600 can be attached to a slot 720 of the rack 700. Instead of fastening the carrier module assembly to the control cabinet, the carrier module assembly 600 can be directly attached to the back panel 740 using fasteners extending through the housing 604. For each slot 720, the back panel 740 includes holes 722 for fastener attachment to the back panel 740.

[0073] like Figure 15 and 26As shown, one or more modules 100 define a control system and together handle or process multiple inputs or multiple outputs. One or more modules 100 may be I / O devices 100a or controllers 100b. An interface 110 of the I / O device 100a may include inputs and outputs, and an interface 110 of the controller 100b may include status indicators. The I / O device 100a and controller 100b handle the inputs and outputs. In some embodiments, the inputs are analog inputs, digital inputs, thermocouple inputs, or RTD inputs. In some embodiments, the outputs are analog outputs or digital outputs. The inputs and outputs (I / O) are typically powered by field sensors and control elements. However, in some embodiments, the digital outputs are powered by one or more modules 100, such as when the digital output is used to energize a relay coil. Field inputs and control outputs are routed to and from control cabinets 300 or racks 700 via a module communication bus 790 extending along all slots. Each module 100 includes a circuit board with a microprocessor, memory, and other circuitry.

Claims

1. A carrier module component, comprising: The module has an interface, a rear plug, and side walls; A carrier frame having a socket adapter and a length, the socket adapter having a first side and a second side, the first side being configured to receive the rear plug of the module; as well as, The carrier stand has a length and a first bus connector configured to intersect with the second side of the socket adapter, and has one or more of a bus port and a second bus connector, wherein... The carrier frame and the carrier upright define a carrier sub-assembly, the carrier sub-assembly being configured to be inserted into a control cabinet, the control cabinet defining at least one slot; and The carrier module assembly includes a length defined by the length of the carrier upright and the length of the carrier frame, wherein the length of the carrier sub-assemblies allows the carrier module assembly to be located within the slot of the control cabinet.

2. The carrier module assembly of claim 1, further comprising a front panel configured to be removably connected to the carrier frame, the front panel having an opening such that the opening provides access to the interface, and the front panel abutting the interface of the module.

3. The carrier module assembly of claim 1, wherein the sidewall of the module is configured to be removably connected to the carrier frame, and the carrier frame is connected to the carrier upright.

4. The carrier module assembly according to claim 1, wherein the length of the module is substantially equal to the length of the carrier frame.

5. The carrier module assembly according to claim 1, wherein the bus port of the carrier stand is configured to interleave with the bus port of the back panel of the control cabinet.

6. The carrier module assembly of claim 1, wherein the second bus connector of the carrier stand is configured to interleave with the bus connector of the process socket adapter.

7. The carrier module assembly of claim 1, wherein the second bus connector of the carrier stand is configured to interleave with the pin connector of the cable.

8. The carrier module assembly of claim 1, wherein the total length of the carrier sub-assembly is in the range of 10 inches (25.4 cm) to 18 inches (45.72 cm).

9. The carrier module assembly of claim 1, further comprising a housing, wherein the carrier frame and the carrier upright are enclosed within the housing, wherein the housing includes a front surface and a side surface, wherein the bus connector of the module is interleaved with a slot disposed on the front surface of the housing.

10. The carrier module assembly of claim 9, wherein a support structure extends from the side surface and is configured to removably secure the module to the housing.

11. A control cabinet, comprising: Back panel, having openings defining multiple slots; At least one of the controller devices or I / O devices is arranged in the first slot of the plurality of slots; At least one carrier module assembly is disposed in a second slot of the plurality of slots, the at least one carrier module assembly comprising: The module has an interface, a rear plug, and side walls; A carrier frame having a socket adapter having a first side and a second side, the first side being configured to receive the plug of the module; and... The carrier stand has a first bus connector configured to intersect with the second side of the socket adapter, and has one or more of a bus port and a bus connector.

12. The control cabinet of claim 11, wherein each of the plurality of slots extends from the front end of the control cabinet to the back panel, and the length of each of the plurality of slots also defines the length of the cabinet, wherein at least one carrier module assembly is fastened to a hole in the slot.

13. The control cabinet of claim 11, wherein the carrier module assembly further includes a housing that encloses the carrier upright and the carrier frame, the housing being configured to be fastened to the back panel.

14. A method for retrofitting a carrier module assembly into a control cabinet, comprising: The conventional equipment is removed from the first slot of the control cabinet and connected to the back panel of the control cabinet; The carrier module assembly is inserted into the first slot, and the controller assembly includes: The module has an interface, a plug, and a surface; A carrier frame having a socket adapter having a first side and a second side, the first side being configured to receive the plug of the module; and... The carrier stand has a first bus connector configured to intersect with the second side of the socket adapter, and has one or more of a bus port and a bus connector; and, Reconnect the pin connector to the bus connector of the carrier stand of the carrier module assembly.

15. The method of claim 14, further comprising the step of removably fastening the front panel to the front surface of the carrier frame.

16. The method of claim 15, wherein the carrier stand has a length, the carrier stand and the carrier frame define a carrier sub-assembly, the total length of the carrier sub-assembly being defined by the length of the connected carrier stand and the length of the connected carrier frame, wherein the carrier sub-assembly is configured and sized to be inserted into the slot of the control cabinet, wherein the total length of the carrier sub-assembly is equal to the length of the conventional equipment.

17. The method of claim 14, wherein before inserting the carrier module assembly into the first slot, the carrier stand is removably connected to the carrier frame, and the carrier frame is removably connected to the module, and the carrier module assembly is assembled by inserting a second side of the receptacle adapter of the carrier frame into the bus connector of the carrier stand, inserting the rear plug of the module into the first side of the receptacle adapter of the carrier frame, and connecting the front panel to the carrier frame.

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