Distributed communication and control system, communication hub and method for configuring reconfigurable connection ports

Abstract

Apparatus and related methods relate to a stackable distributed communication and control hub (DCCH), which is configured to provide a wide viewing angle for instantly checking multiple connections when multiple DCCHs are stacked. In an illustrative example, the DCCH may include multiple connection ports distributed on one or more edge surfaces. For example, an offset bracket may couple two DCCHs, each DCCH being located on a coupling surface of a corresponding DCCH. When coupled, the DCCHs remain on substantially parallel planes. For example, a first DCCH is offset from a second DCCH in two directions. In a first direction, the planes are offset by a predetermined first offset along a vertical axis. In a second direction orthogonal to the first direction, the DCCH is offset by a predetermined second offset. Various embodiments may advantageously allow the visual state of a connection port to be visible in at least one viewing angle along the vertical axis.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 270,938, filed on October 22, 2021 by Robert T. Fayfield et al., entitled “Distributed Communication and Control System using Concurrent Multi-Channel Master Unit.”

[0003] This application is a continuation-in-part of WIPO application serial number DM / 222576, entitled “COMMUNICATION HUB,” filed by Banner Engineering Corp. on April 21, 2022, and claims priority, which also claims the benefit of U.S. provisional application serial number 63 / 270,938, entitled “Distributed Communication and Control System using Concurrent Multi-Channel Master Unit,” filed by Robert T. Fayfield et al. on October 22, 2021.

[0004] This application is a continuation-in-part of WIPO application serial number DM / 222908, entitled “COMMUNICATION HUB OFFSET STANDOFF BRACKET,” filed by Banner Engineering Corp. on April 21, 2022, and claims priority, which also claims the benefit of U.S. provisional application serial number 63 / 270,938, entitled “Distributed Communication and Control System using Concurrent Multi-Channel Master Unit,” filed by Robert T. Fayfield et al. on October 22, 2021.

[0005] The present application incorporates by reference the entire contents of each of the above applications. Technical Field

[0006] Various embodiments generally relate to network communications.

[0007] background

[0008] A manufacturing facility and / or factory may include a large number of devices. These devices may include various actuators and sensors. For example, actuators may include machines, conveyor belts, conditioning facilities (e.g., air conditioners, humidifiers), status indicators, and other actuators used to manufacture a specific product in the factory. Sensors may include, for example, temperature sensors, touch sensors, tracking sensors, safety sensors, etc. These actuators and / or sensors may be specifically installed in a manufacturing workshop, for example, for producing a product.

[0009] For various products, the production of the product may include more than one manufacturing process. Each manufacturing process may include various procedures. In some cases, each manufacturing procedure may include a set of discrete actuators and sensors. For example, each set of actuators and sensors may require a separate control system.

[0010] As an illustrative example, in clothing manufacturing, a manufacturer may use multiple automatic cutting machines controlled by cutting machine controllers in the cutting department, and use a separate production tracking system for each production line. Typically, the cutting machine controllers and the production tracking system may use different communication protocols. Sometimes, factory management may require workers to manually input data collected from various systems in the factory into a third computer system to analyze and manage the factory's entire production process.

[0011] Other facilities can use actuators and / or sensors. For example, warehouses (e.g., distribution warehouses) can use actuators and / or sensors. For example, office buildings can deploy actuators and / or sensors. In some examples, retail facilities can deploy actuators and / or sensors. For example, military facilities can use actuators and / or sensors. Residential facilities (e.g., multi-family homes, single-family homes, hotels) can use actuators and / or sensors. Hospitality facilities (e.g., restaurants, hotels, hospitals) can use actuators and / or sensors. Medical and / or research facilities can, for example, use actuators and / or sensors. Educational facilities can, for example, use actuators and / or sensors.

[0012] Overview

[0013] Apparatus and related methods relate to a stackable distributed communication and control hub (DCCH) configured to provide a wide viewing angle for instantly checking multiple connections when multiple DCCHs are stacked. In an illustrative example, the DCCH may include multiple connection ports distributed on one or more edge surfaces. For example, an offset bracket may couple two DCCHs, each DCCH being located on a coupling surface of a corresponding DCCH. When coupled, the DCCHs remain on substantially parallel planes. For example, a first DCCH is offset from a second DCCH in two directions. In a first direction, the planes are offset by a predetermined first offset along a vertical axis. In a second direction orthogonal to the first direction, the DCCH is offset by a predetermined second offset. Various embodiments may advantageously allow the visual state of a connection port to be visible in at least one viewing angle along the vertical axis.

[0014] Various embodiments may achieve one or more advantages. For example, some embodiments may include a second offset bracket releasably coupled to a third DCCH offset in a third direction relative to the first DCCH to advantageously provide a wide viewing angle for the connection of all three stacked DCCHs. Some embodiments may, for example, include a threaded insert at the offset bracket so that a lead-in channel for a fastener may be advantageously provided.

[0015] Apparatus and related methods relate to a dynamically reconfigurable DCCH that is configured to independently and automatically identify and configure each of its multiple connection ports. In an illustrative example, the DCCH may include a controller circuit and multiple independent reconfigurable connection ports (IRCPs). For example, the DCCH may be connected to multiple edge devices and controllers at the IRCP. The edge devices and controllers may use different communication protocols. For example, when a signal is received at the IRCP, the control circuit may retrieve a first predetermined set of rules to determine whether the IRCP is operated as a master port, a slave port, or a pass-through port. For example, based on a second set of rules, the control circuit may determine the communication protocol of the IRCP. Various embodiments may advantageously avoid manual intervention in setting each of the multiple IRCPs of the DCCH.

[0016] Various embodiments may achieve one or more advantages. For example, some embodiments may automatically associate a preconfigured virtual address with a device address of an edge device to advantageously provide a reference address to the edge device. For example, some embodiments may include an interrupt thread to advantageously improve the response time of the DCCH. Some embodiments may include, for example, a user rules engine to advantageously allow customization of the DCCH response. For example, some embodiments may include globally accessible shared registers to advantageously allow system-wide access to measurements of edge devices.

[0017] Apparatus and related methods relate to an in-line signal processing device (ISPD) configured to serially connect two or more devices via one or more ISPDs. In an illustrative example, the ISPD may include an overmolded housing and two connection ports. The electronic circuit may, for example, include a data register and a processing circuit configured to generate a signal based on a predetermined conversion. For example, the overmolded housing may completely encapsulate the electronic circuit in an integral body such that the total thickness of the in-line signal processing device is less than a predetermined multiple of the maximum size of the connection port. Various embodiments may advantageously provide a dustproof ISPD.

[0018] Various embodiments can achieve one or more advantages. Some embodiments can include, for example, a status indicator configured to advantageously provide a visual indicia of status. For example, some embodiments can include a substantially transparent layer of polymeric material to advantageously allow the visual indicia of status to be emitted through the overmolded housing. Some embodiments can, for example, include a sensing circuit to advantageously provide a sensor function at the ISPD. Some embodiments can include, for example, a functional parameter for selecting a customized response of the ISPD.

[0019] Apparatus and related methods relate to self-calibrating in-line thermistors. In an illustrative example, an internal sensor circuit can be coupled to an analog-to-digital converter (ADC). For example, during each measurement cycle, the in-line thermistor is dynamically calibrated by reading a reference voltage, an input voltage, and a ground voltage of the ADC. Various embodiments can advantageously eliminate the need for an external reference voltage to save circuit size.

[0020] Various embodiments may achieve one or more advantages. Some embodiments may include, for example, an IO-Link protocol to advantageously communicate with other IO-Link compatible devices. For example, some embodiments may include a Modbus protocol to advantageously couple to a control network.

[0021] The details of various embodiments are set forth in the drawings and the description that follows. Other features and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Depicted are exemplary distributed communications and control architectures in illustrative use case scenarios.

[0024] Figure 2 is a flow chart illustrating an exemplary method for connecting a distributed communication and control system to a plurality of devices.

[0025] Figure 3 , Figure 4 and Figure 5 Depicted are exemplary distributed communications and control systems in illustrative use case scenarios.

[0026] Fig. 6A An exemplary in-line converter is depicted.

[0027] Figure 6B Depicted as a reference Fig. 6A A flow chart of an exemplary method for creating an exemplary shell using an exemplary online converter is described.

[0028] Figure 6C A flow chart of an exemplary signal processing method for an exemplary in-line converter is depicted.

[0029] Figure 7 Depicted is an exemplary online converter in an illustrative use case scenario.

[0030] Fig. 8A and Figure 8B An exemplary in-line converter is depicted.

[0031] Fig.9A , Fig. 9B , Fig. 10A , Fig. 10B , Fig. 10C and Fig. 10D Various views of an exemplary in-line converter are depicted.

[0032] Fig.11A , Fig. 11B , Fig. 11C , Fig.11D and Fig.12 An exemplary in-line converter and associated exemplary electrical and logical architectures of the exemplary in-line converter are depicted.

[0033] Fig.13 An exemplary sensing circuit that may be used in an exemplary in-line converter is depicted.

[0034] Fig.14A and Fig. 14B An exemplary temperature and humidity sensor is depicted.

[0035] Fig.15A , Fig. 15B , Fig.16A , Fig. 16B , Fig. 16C and Fig.16D An exemplary communication hub is depicted.

[0036] Fig.17 An exemplary dynamically configurable control hub (DCCH) is depicted.

[0037] Fig.18 and Fig.19 An exemplary block diagram of an exemplary DCCH is depicted.

[0038] Fig. 20 , Fig.21 , Fig. 22 , Fig.23 and Fig.24 Depicted is an exemplary DCCH deployed in an illustrative use case scenario.

[0039] Fig.25 A flow chart of an exemplary signal processing method for an exemplary DCCH is depicted.

[0040] Fig.26 A flow chart illustrating an exemplary connection port reconfiguration method for an exemplary DCCH is shown.

[0041] Fig. 27 A flow chart of an exemplary configuration method of an exemplary DCCH is depicted.

[0042] Fig.28 A flow chart of an exemplary writing method of an exemplary DCCH is depicted.

[0043] Fig.29A , Fig.29B , Fig.29C , Fig.29D and Fig.29E A perspective view, front view, left side view, right side view, and top view, respectively, of an illustrative DCCH are depicted.

[0044] Fig.29F A perspective view of an exemplary DCCH coupled to a mounting bracket is depicted.

[0045] Figure 29G Depicted Fig.29F A mounting bracket configured to couple the DCCH to the rail.

[0046] Fig.29H Depicted Fig.29F A mounting bracket configured to magnetically mount the DCCH.

[0047] Fig.30 Depicted are exemplary stackable DCCHs in an illustrative stacking use case scenario.

[0048] Fig.31A , Fig.31B , Fig.32A , Fig.32B , Fig.32C and Fig.32D Describes Fig.30 An exemplary DCCH stacking bracket is shown.

[0049] Fig.33A , Fig.33B , Fig.33C and Fig.33D An exemplary DCCH stack support is depicted.

[0050] Fig.34 and Fig.35 Depicted are exemplary stackable DCCHs in an illustrative offset stacking use case scenario.

[0051] Fig.36 , Fig.37A and Fig.37B Depicted is an exemplary stackable communications hub in an illustrative alternating offset stacking use case scenario.

[0052] Fig.38 , Fig.39 , Fig.40 , Fig.41 and Fig.42 Depicted are exemplary distributed communications and control systems in illustrative use case scenarios.

[0053] Fig.43 An exemplary distributed communications and control architecture with remote communications is depicted.

[0054] Fig.44 An exemplary telecommunications gateway is depicted.

[0055] Fig.45 An exemplary remote communication hub is depicted in an illustrative use case scenario in an exemplary distributed communication and control system.

[0056] Fig.46 Depicted are an exemplary configurable multi-output safety controller in an illustrative use case scenario in an exemplary distributed communications and control system.

[0057] Like reference numbers in the various drawings represent like elements.

[0058] DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0059] To aid understanding, this document is organized as follows. First, to help introduce the discussion of various embodiments, refer to Figure 1-Figure 2 Introduces distributed communication and control architectures. Second, this introduction leads to reference Figure 3-Figure 5 A description of some exemplary embodiments of distributed communication and control systems. Figure 6A-Figure 12 , describes an online converter applied to an exemplary distributed communication and control system. Fourth, reference Figure 13-14B , the discussion turns to an exemplary embodiment showing a compact form factor in-line thermistor. Fifth, with reference to Figure 15A-Figure 28 , this document describes exemplary apparatus and methods for implementing and using a distributed communication and control hub. Sixth, the present disclosure turns to reference Figure 29A-Figure 42 Describes exemplary apparatus and methods for stackable distributed communication and control hubs. Figure 43-Figure 46Various control systems and applications using a distributed communication and control architecture are introduced. Finally, this document discusses further embodiments, exemplary applications and aspects related to methods and apparatus for distributed communication and control systems.

[0060] Figure 1 An exemplary distributed communication and control architecture in an illustrative use case scenario is depicted. System 100 includes an edge device 105. Edge device 105 may, for example, include inputs and / or outputs. In the described example, edge device 105 includes discrete sensor 110. Edge device 105 also includes analog sensor 115. Edge device 105 includes IO-link tower light 120. Edge device 105 also includes serial Modbus device 125 (e.g., sensor). Edge device 105 may, for example, form a capture layer 122 of system 100. Capture layer 122 may, for example, include data collection and / or display. For example, capture layer 122 may include sensors. Capture layer 122 may include indicators. Capture layer 122 may, for example, include interfaces (e.g., human-machine interface, machine-machine interface).

[0061] In the described example, the edge devices 105 are connected in the connection layer 132. As shown, some edge devices 105 are connected to the system 100 via online connectors 130. As an example and not a limitation, some embodiments may include one or more online connectors 130 configured to perform signal / protocol conversion, which may be advantageous. Some edge devices 105 are connected to the system 100 via multi-branch connectors 135 (e.g., "three-way" connectors). Some edge devices 105 can be connected to the system 100 and one or more other systems and / or devices via a shunt connector 140. The connector may, for example, include a standard connector (e.g., BNC, bayonet, 4-pin, 3-pin, M8, M12). The connector may, for example, include a proprietary connector. In some embodiments, the connector may be integrated into the edge device 105 and / or other members of the system 100.

[0062] Some edge devices 105 may, for example, send and / or receive signals in different forms and / or according to different protocols. As depicted as an illustrative example, some edge devices 105 may be analog (e.g., ±10V, ±20V, based on current), some may be discrete (e.g., binary, discrete digital values), some may use serial communication protocols, some may use various digital protocols, or some combination thereof. The system 100 may use one or more predetermined communication protocols. For example, the system 100 may be configured to receive and / or send data to the edge device 105 using at least a first protocol. The first protocol may, for example, include IO-Link (e.g., currently managed by the "PI North America" ​​trade association in North America and at least partially defined by the International Electrotechnical Commission (IEC) 61131-9). The system 100 may be configured to receive and / or send data between a communication hub, a control device, and / or a remote system using at least a second protocol. The second protocol may, for example, include Modbus (e.g., at least partially defined by a specification published by the Modbus organization in Massachusetts, USA). In various embodiments, signals may be received, sent, interpreted, and / or generated between a first protocol, a second protocol, or other protocols.

[0063] For example, the conversion layer 142 may include one or more conversion devices. As shown, the online converter 145 can be configured to receive a signal in a first protocol and generate a corresponding signal in a second protocol and / or a third communication protocol, or vice versa, or some combination thereof. In some embodiments, for example, the online converter 145 can be configured to facilitate bidirectional communication between one or more edge devices 105 and one or more upstream devices in the local communication protocol of each device. In the described example, the first online converter 145a is configured to receive an analog signal (e.g., from an analog sensor 115) and generate a corresponding signal according to the IO-Link protocol, or vice versa. In addition, in the described example, the second online converter 145b is configured to receive a discrete signal (e.g., from a discrete sensor 110) and generate a corresponding signal according to the IO-Link protocol, or vice versa.

[0064] A communication hub 155 is further depicted in the conversion layer 142. In the described example, the communication hub 155 is configured to communicate at least in the IO-Link protocol. For example, the communication hub 155 can be configured (as shown) as an IO-Link hub. The communication hub 155 is depicted as, for example, a hub for receiving and / or sending signals from discrete sensors 110. Other ports of the communication hub 155 connected to the discrete sensors 110 can, for example, be configured so that each port communicates with one or more other devices (e.g., edge devices 105, communication devices, control devices).

[0065] As shown, the network layer 152 includes one or more communication control devices. For example, the second communication hub 155 is depicted as being coupled to the first communication hub 155, the first online converter 145a, and the IO-link tower light 120. The communication hub 155 can, for example, be configured with one or more ports as IO-Link master devices (e.g., initiating read and / or write operations). The second communication hub 155 can, for example, control communications between connected devices.

[0066] Also included in the depicted network layer 152 is a wireless communication device 160. The wireless communication device 160 may, for example, include one or more base units and / or one or more remote units. For example, the remote units of the wireless communication device 160 are depicted as being coupled to the multi-drop connector 135, thereby connecting to the serial Modbus device 125. The remote units can communicate wirelessly with the base units of the wireless communication device 160. The base units can be connected to upstream devices. Thus, various remote edge devices 105 can be advantageously coupled to the system 100.

[0067] As shown, the distribution layer 162 includes a control hub 165. The control hub 165 can communicate, for example, in a second protocol. In the described example, the control hub 165 is configured to communicate at least in a Modbus protocol. As shown, the control hub 165 is coupled to the communication hub 155, the base unit of the wireless communication device 160, and the second online converter 145b. Therefore, in the example shown, the control hub 165 is coupled to at least 6 of the edge devices 105. The control hub 165 can be configured to receive data from the edge device 105. The control hub 165 can be configured to generate data based on received data, received commands, predetermined data, predetermined instructions, or some combination thereof. The control hub 165 can be configured, for example, to send received and / or generated data in response to a received request, a predetermined instruction, predetermined data, or some combination thereof. The control hub 165 can, for example, apply one or more predetermined rules to the received data. The control hub 165 may, for example, receive instructions from one or more external control devices (e.g., a programmable logic controller (PLC), a remote control system, an operator interface). In some embodiments, the control hub 165 may, for example, transmit data to a remote device (e.g., via Ethernet).

[0068] In the depicted example, the distribution layer 162 also includes a remote communication gateway 170. The remote communication gateway 170 can, for example, send and / or receive data between the control hub 165 and a remote input, visualization, and / or control system. For example, the remote communication gateway 170 can be configured to transmit data between the control hub 165 and a remote visualization and / or cloud system. In various exemplary embodiments, by way of example and not limitation, the remote communication gateway 170 can include, for example, a gateway commercially known as an "edge gateway" and / or a "DXM fusion gateway."

[0069] In the described example, the consumption layer 172 includes a cloud network 175. The consumption layer 172 also includes one or more visualization devices 180. The one or more visualization devices 180 may, for example, include general-purpose devices (e.g., servers; personal computers; mobile computing devices such as smartphones, tablets, laptops, smart watches). For example, the one or more visualization devices 180 may include specially built devices (e.g., dedicated interfaces). The one or more visualization devices 180 may, for example, include dynamically generated interfaces (e.g., via a cloud platform). For example, the one or more visualization devices 180 may be coupled to the cloud network 175. The cloud network 175 may, for example, operably couple one or more systems (e.g., physically separated, physically remote) to the system 100. In some embodiments, the cloud network 175 may provide selected data to the system 100 and / or one or more visualization devices 180 (e.g., to managers, engineers, quality assurance personnel). The cloud network 175 may, for example, apply remote processing (e.g., machine learning algorithms) to data from the system 100 (e.g., originating from the edge device 105). In some embodiments, the cloud network 175 can provide data and / or commands back to the system 100 (e.g., via the remote communication gateway 170, to an edge control and / or communication device, such as the control hub 165, to one or more centralized control systems, and then to the system 100).

[0070] Thus, various embodiments may advantageously enable a decentralized system of potentially disparate edge devices to be quickly and / or cost-effectively coupled into a cohesive communication and / or control system. Various embodiments may advantageously allow edge processing in a decentralized system. Such embodiments may, for example, reduce latency. Some embodiments may, for example, reduce the burden on a central processing device. Some embodiments may advantageously allow (substantially) real-time communication and processing between local devices (e.g., indicators, actuators, sensors) in response to received data. Some embodiments may advantageously allow critical data to be selectively sent to upstream visualization, monitoring, and / or control devices. Various such embodiments may advantageously reduce communication bandwidth requirements and / or system communication costs (e.g., wiring, labor, accidentally disconnected cables, tripping hazards).

[0071] Various embodiments may, for example, advantageously enable process optimization (e.g., by providing remote access and / or monitoring to more devices, by providing edge processing for responsive processes that were previously not possible due to processing delays and / or communications infrastructure costs). Various embodiments may, for example, advantageously enable enhanced dashboards and / or visualizations (e.g., by providing greater access to edge devices). Various embodiments may, for example, advantageously provide enhanced condition monitoring. Some embodiments may advantageously enable predictive maintenance (e.g., minimizing downtime), for example, due to enhanced data collection, connectivity, and / or processing.

[0072] Various embodiments can advantageously enable rapid and / or cost-effective modernization of equipment. For example, distributed connections, conversions, and / or processing can advantageously unlock valuable information from legacy equipment.

[0073] Various embodiments can advantageously facilitate (field) integration of various devices into new and / or existing systems. For example, some embodiments can advantageously provide an easily expandable system that is configured to remotely collect and / or monitor data.

[0074] Figure 2 1 is a flow chart illustrating an exemplary method 200 for connecting a distributed communication and control system to a plurality of devices. For example, the method 200 may be used to install the system 100 when a new plant is being built. In some examples, the method 200 may be used to install the system 100 in an existing plant with legacy devices. For example, the system 100 may be configured to monitor new compatible devices and legacy devices that may require signal conversion. In some implementations, the method 200 may be at least partially automatically performed by one or more computing devices (e.g., running automatic configuration software).

[0075] In this example, the method 200 begins when all devices that need to be monitored are identified in step 205. Next, a quick connect splitter cable and converter are added to transfer the signal to Modbus in step 210. For example, the splitter connector 140 and the inline converter 145 can be used to connect the edge device 105 to the Modbus network.

[0076] In step 215, the identified devices are connected to a single Modbus network. For example, the edge device 105 can be connected to the Modbus network in the network layer 152. After the identified devices are connected to the single Modbus network, in step 220, the data is pushed to the cloud network using a gateway controller. For example, the data collected in the capture layer 122 can be transmitted upward to the distribution layer 162 and the cloud network 175 via the remote communication gateway 170. In step 225, the cloud service is used to monitor the identified devices.

[0077] In decision point 230, it is determined whether a data analysis report is to be generated. If a data analysis report is to be generated, then in step 235, the data analysis report is generated and sent to a visualization device (e.g., one or more visualization devices 180), and the method 200 ends. If a data analysis report is to be generated, then the method 200 ends.

[0078] Figure 3 , Figure 4 and Figure 5 An exemplary distributed communications and control system in an illustrative use case scenario is depicted. For example, various embodiments can be configured to "overlay" a distributed communications and / or control system (DCCS) onto existing equipment and / or systems. In the exemplary scenario 300, the edge devices 105 are already in place and operating according to the existing configuration. In the described example, the edge devices 105 are configured around a conveyor line 305. The conveyor line 305 can be monitored, for example, by optical sensors (e.g., distance measurement) and / or proximity sensors. Visual markers can be generated by tower lights (e.g., operating status). The edge device 105 can, for example, be connected to an existing control system (e.g., a machine controller).

[0079] In the described example, the DCCS is operably "superimposed" onto an existing control system using an existing edge device 105 by coupling each edge device to a shunt connector 140. The shunt connector 140 is connected to the existing control system and to the superimposed DCCS. The superimposed DCCS can communicate at the described system level, for example, in a first protocol (e.g., IO-Link). The output of the shunt connector 140 is appropriately coupled to the DCCS via an online converter 145 (e.g., analog to IO-Link, discrete to IO-Link). In the described example, the communication hub 310 can, for example, be configured to receive a signal from the edge device 105. The communication hub 310 can, for example, generate a signal and send the signal to a central location (e.g., cloud network 175) in response to input from the edge device 105. The communication hub 310 can, for example, generate a signal and send the signal to the edge device 105 in response to input from the central location. Various embodiments can advantageously provide a public network operating according to one or more common protocols.

[0080] In the exemplary scenario 400, an existing imprint system 405 (e.g., an example of an edge device 105) includes a tower light 410. The existing edge device 105 is configured relative to the imprint system 405 (e.g., the tower light 410 indicates the operating status of the imprint system 405). The DCCS system is superimposed on the existing system (e.g., while maintaining communication between the existing edge device 105 and the existing control system). As shown, the existing edge device 105 is coupled to the remote communication gateway 170 via an online converter 145 (e.g., converting the communication protocol of the tower light to a common communication protocol).

[0081] Additional optical sensors 415 (e.g., examples of edge devices 105) are added relative to the imprint system 405 via the DCCS. For example, additional information about the imprint system 405 may be needed (e.g., the positioning of the part, the current position of the operator shield). In the described example, the optical sensor 415 is added and coupled to the remote communication gateway 170 via the multi-drop connector 135. The remote communication gateway 170 can, for example, process and / or transmit data to a remote system (e.g., a cloud network 175, one or more visualization devices 180). Overlaying the DCCS onto an existing network can, for example, advantageously allow for rapid and / or cost-effective (e.g., with additional edge devices 105, with edge processing) expansion and / or extension while avoiding replacement of existing control systems and / or edge devices.

[0082] In exemplary scenario 500, a DCCS may be deployed relative to machine 505. For example, a control hub 165 may be provided as a communication and control hub. Control hub 165 may, for example, connect the DCCS to an upstream control and / or monitoring system (e.g., via Ethernet / IP, Modbus, ). The control hub 165 can, for example, provide configurable edge processing (e.g., in response to signals from connected edge devices 105). Various edge devices 105 can be implemented relative to the machine 505 via the control hub 165. In the described example, a first protocol sensor 510 (e.g., a pressure gauge and a current transformer as described from left to right) can be coupled to the control hub 165 via an appropriate online converter 145 (e.g., an appropriate protocol ←→ Modbus). As an illustrative example and not limiting, for example, the pressure gauge shown in some embodiments may include a 2 / 3 wire configuration. Other implementations are also possible. IO-Link and / or Modbus-enabled sensors 515 (e.g., a vibration sensor and a temperature and / or humidity sensor as shown from left to right) can be directly coupled to the control hub 165. In the described example, the first protocol sensor 510 and the Modbus-enabled sensor 515 are directly coupled to the (single) first port of the control hub 165 (via a three-way coupler). The first port of the control hub 165 may communicate with the connected edge device 105 , for example, via the Modbus protocol (eg, with the help of an in-line converter 145 with respect to the first protocol sensor 510 ).

[0083] A second port of the control hub 165 is coupled to a sensor 520 via an in-line converter 145. As an illustrative example and not a limitation, the sensor 520 of the illustrated example may be a 3-wire voltage sensor (e.g., 0-10V) or a current sensor (e.g., 4-20mA). A third port of the control hub 165 is directly coupled to a sensor 525. Thus, a system of available and / or desired edge devices 105 implemented with different communication systems can be advantageously (e.g., quickly and cost-effectively) assembled and configured into a DCCS to instrument and / or control a machine 505. The DCCS can be connected to an external system, for example, via the control hub 165. In some embodiments, the control hub 165 can advantageously facilitate communication between channels having, for example, different baud rates and / or parity settings. For example, the control hub 165 can provide buffering and / or appropriate conversion services to support communication between ports that are, for example, electrically or optically coupled to signals formatted with otherwise incompatible communication characteristics.

[0084] Fig. 6AAn exemplary online converter is depicted. The online converter 605 (e.g., configured as disclosed at least with reference to the online converter 145) can, for example, be configured to convert between analog and IO-Link. For example, the online converter 605 can be configured to convert between analog and Modbus. For example, the online converter 605 can be configured to transfer analog directly to analog ("pass-through"). For example, the online converter 605 can be configured to convert between PWM / PFM (pulse width modulation and / or pulse frequency modulation) and Modbus. For example, the online converter 605 can be configured to convert between PWM / PFM and analog. For example, the online converter 605 can be configured to convert between PWM / PFM and IO-Link. In the described example, the online converter 605 configured for analog can be configured to process (e.g., receive, send) signals between 10-30VDC.

[0085] Various embodiments may advantageously allow existing edge devices to quickly adapt to new systems (e.g., by coupling to the new system via appropriate in-line converters). Various embodiments may advantageously convert between industry standard protocols and / or between proprietary protocols, for example. Various embodiments may advantageously link legacy (e.g., analog, discrete) edge devices into "smart" systems.

[0086] In the depicted example, the inline converter 605 is configured with an M12 male / female connection.Such an embodiment may, for example, advantageously allow the connection to be made using common industry standard physical connectors and / or cables.

[0087] In some embodiments, the online converter 605 can be configured with a housing, which, by way of example and not limitation, has an outer diameter of about 15 mm. For example, such an embodiment can be advantageously deployed in a small area. Some embodiments can, for example, have a diameter similar to that of a cable and / or an existing connector. For example, in some embodiments, the online converter 605 can be less than and / or equal to 2 times the diameter of a cable and / or connector. In some embodiments, the online converter 605 can be less than and / or equal to 1.5 times the diameter of a cable and / or connector. In some embodiments, the online converter 605 can be substantially the same as the diameter of a cable and / or connector (e.g., within manufacturing tolerances, e.g., by way of example and not limitation, between 0.9x-1.1x of the diameter of a cable and / or connector). In some embodiments, the online converter 605 can have an effective diameter less than that of a cable and / or connector. Various embodiments can advantageously provide plug-in, monitored sensor and / or connector solutions of a small form factor.

[0088] In some embodiments, the online converter 605 can be preconfigured for one or more specific applications. In this example, the online converter 605 includes a circuit 605A (e.g., an internal circuit). As shown, the circuit 605A includes a processing circuit 610. For example, the processing circuit 610 may include a programmable logic circuit (PLC). For example, the processing circuit 610 may include an application specific integrated circuit (ASIC). For example, the processing circuit 610 may include a register 615 (e.g., a data register, an EEPROM). In some embodiments, the processing circuit 610 may receive a configuration signal from an intelligent controller (e.g., a control hub 165).

[0089] In this example, the online converter 605 includes a sensor 620. For example, the online converter 605 can be preconfigured for a specific sensing (e.g., temperature reading in ° C and / or ° F, pressure reading in desired pressure units) and / or indication application. As shown, the sensor 620 can transmit sensor data in the register 615. In some embodiments, the online converter 605 can be preconfigured for a specific protocol combination between the input-output ports 625a, 625b (e.g., Modbus←→IO-Link, analog←→IO-Link). For example, the preconfiguration can be hardwired. The preconfiguration can be implemented, for example, by one or more configuration parameters (e.g., a configuration profile stored in the register 615). Such an embodiment can, for example, promote rapid deployment with a minimum configuration of each component. In some embodiments, the system can be, for example, a planned and preconfigured component (e.g., an online converter 605), and then quickly physically deployed. For example, some embodiments can provide a "plug and play" function.

[0090] In some embodiments, the online converter 605 may be provided with one or more status indicators 630. The status indicator 630 may, for example, include one or more light emitting diodes (LEDs). The status indicator 630 may, for example, be configured to generate a visual indication in response to the state of the online converter 605. The state and corresponding indication may, for example, be predetermined (e.g., in a configuration profile on the online converter 605, hardwired), determined by a remote device (e.g., a control hub 165), or some combination thereof. For example, the status indication may facilitate rapid troubleshooting. For example, a technician may quickly browse each connector and determine the state. For example, a technician may quickly visually identify one or more connectors in a desired state (e.g., an error state) based on the visual indication generated by the online converter. The technician may then troubleshoot a particular connected device.

[0091] In some embodiments, the status indicator 630 may be visible, for example, through the housing 635 of the online converter 605. For example, the body may be at least partially translucent. The status indicator 630 may, for example, be coupled (e.g., disposed) on a circuit board within the body of the online converter 605. For example, when the status indicator 630 is off, the status indicator 630 may not be visible from an external view through the body of the online converter 605. For example, the interior of the body may not be visible. When one or more status indicators 630 are turned on, a visual indication (e.g., light, color, pattern) may be visible through the housing of the body.

[0092] In some embodiments, the housing 635 is a (at least partially rigid) structure. For example, the housing 635 can define the structure of the body of the in-line converter 605. In some embodiments, the housing 635 can be overmolded. For example, the housing 635 can completely encapsulate the in-line converter 605 as a whole. For example, the housing 635 can be overmolded to advantageously keep the in-line converter 605 dustproof (e.g., rated IP65, IP67, IP68).

[0093] In some embodiments, as shown, the in-line converter 605 can be configured as a substantially cylindrical shape. In some embodiments, the in-line converter 605 can be configured as a rectangular prism. In some embodiments, the in-line converter 605 can be configured as an irregular shape.

[0094] In some embodiments, such as depicted, having a substantially cylindrical outer surface, the inline converter 605 can advantageously be configured in a desired orientation during deployment. For example, the absence of flats, feet, and / or accessory extensions can advantageously allow the inline converter 605 to be viewed as part of the cable. By way of example and not limitation, the inline converter 605 can advantageously be rotated about the transmission path of the cable to present a desired orientation (e.g., maximum visibility of one or more indications).

[0095] In some embodiments, the indication can be configured to have a wide field of view (eg, greater than 90 degrees, in some embodiments greater than 180 degrees). In some embodiments, the indication can be configured to be substantially circumferential (eg, substantially 360 degrees).

[0096] Figure 6B Depicted as reference Fig. 6A Flow chart of an exemplary method 650 for creating an exemplary housing for an exemplary inline converter. For example, a manufacturer of inline converter 605 can use method 650 to overmold housing 635 to encapsulate inline converter 605.

[0097] In this example, method 650 begins when an in-line converter circuit is provided for overmolding in step 655. For example, the in-line converter circuit may include processing circuit 610, register 615, status indicator 630, and / or sensor 620. In step 660, the array of in-line converter circuits is underfilled. For example, the in-line converter circuit underfill may prevent the in-line converter circuit from breaking during the overmolding process. In some embodiments, housing 635 may be defined at least in part by overmolding of material around one or more circuits and / or related structures.

[0098] Next, in step 665, a first polymeric material may be molded around the inline converter circuit to form a body. For example, the first polymeric material may be at least partially translucent. For example, the first polymeric material may have a first optical transparency. In step 670, a second polymeric material is molded around at least some of the first polymeric material, and method 650 ends. For example, the second polymeric material may have a second optical transparency. In some embodiments, the first optical transparency may be greater than the second optical transparency. In some embodiments, the thickness of the first polymeric material (e.g., the radial length relative to the longitudinal axis of the inline converter 605) may be greater than the thickness of the second polymeric material. For example, the second polymeric material may be a relatively thin coating covering the first polymeric material. The second polymeric material may optically block the contents of the body from being seen unless the indicator (one or more) is active. In some embodiments, by way of example and not limitation, the thickness of the second polymeric material may be 2 mm or less. In some embodiments, the total thickness of the inline converter 605 may be less than 1.5 times the maximum thickness of the input port 625a and the output port 625b.

[0099] Figure 6C A flow chart of an exemplary signal processing method 675 of an exemplary online converter is depicted. For example, the online converter 605 can process an input signal using the method 675. In this example, the method 675 starts when an input signal is received at an input port in step 680. For example, the input signal can be sent from one of the edge devices 105. Next, in step 685, the input signal is processed based on the settings in the configuration register to generate an output signal at the output port. For example, the processing circuit 610 can process an input signal received at an IO port 625a based on the settings stored in the register 615 to generate an output signal at an IO port 625b. For example, the input signal can be in a non-IO-Link compatible analog format. For example, the online converter 605 can generate an IO-Link signal based on the input signal.

[0100] In decision point 690, it is determined whether a visual indicia (e.g., a good connection visual indicator) is generated at the status indicator (e.g., status indicator 630). If a visual indicia is to be generated at the status indicator, a signal is generated in step 695 to activate the status indicator, and method 675 ends.

[0101] Figure 7 An exemplary online converter in an illustrative use case scenario is depicted. In scenario 700, an IO-Link hub 705 can be configured to communicate with multiple devices. For example, a device can be coupled to the IO-Link hub 705 via a cable 710. A Modbus sensor 715 (e.g., an edge device) can be coupled to the IO-Link hub 705, but the machine may not be able to communicate with the IO-Link hub 705. The modbus sensor 715 can be, for example, a vibration and / or temperature sensor. The Modbus sensor 715 can be coupled to the IO-Link hub 705 via an online connector 720 (e.g., Modbus←→IO-Link).

[0102] The IO-Link hub 705 can be coupled to a (e.g., newly added) non-IO-Link sensor 725 via an in-line converter 605. For example, reference can be made to Fig. 6A In-line converter 605 is described. In some implementations, in-line converter 605 can be a "universal" connector (e.g., automatically and / or manually configurable between multiple modes and / or communication protocols). Thus, various embodiments can advantageously allow for utilization of open IO-Link ports (e.g., utilization of non-IO-Link (edge) devices). For example, a non-IO-Link device can send an incompatible signal (e.g., an analog signal, a discrete signal, a PWM signal) to communication hub 155 or control hub 165. Various embodiments can convert the incompatible signal into a compatible signal for use with other components of system 100.

[0103] As in other communication hub, converter and / or device embodiments herein, IO-Link and / or Modbus are provided as illustrative examples. In some embodiments, a device (e.g., hub 705) may employ one or more additional signal types and / or communication standards in addition to IO-Link and / or Modbus. In some embodiments, for example, a device (e.g., hub 705) may not be configured for Modbus and / or IO-Link.

[0104] Fig. 8A and Figure 8BAn exemplary online converter is depicted. The online converter 800 may include a first end 805 (e.g., a female 5-pin coupler). The online converter 800 may have a second end 810 (e.g., a male 5-pin coupler). The online converter 800 may have a body 815. As shown, the body 815 is threaded. For example, the threaded body can advantageously enable the online converter 800 to be (releasably) coupled to a housing and / or a mounting member. As shown, the online converter 800 includes a first indicator 820 (e.g., green) and a second indicator 825 (e.g., yellow). Indicators 820, 825 can, for example, be configured to display a visual indication of the status (e.g., operation, error state, sending, receiving, connection) of the online converter 800 and / or the connected device.

[0105] Fig.9A , Fig. 9B , Fig. 10A , Fig. 10B , Fig. 10C and Fig. 10D Various views of an exemplary in-line converter are depicted. In-line converter 605 is depicted in perspective view 900 and cross-sectional view 901. In-line converter 605 may, for example, have circuitry (not shown) disposed in the body of in-line converter 605. For example, the circuitry may include processing circuitry 610. Indicators (e.g., status indicators 630) may, for example, be disposed in the open cavity shown in the body of in-line converter 605. In some embodiments, the open cavity may be (completely) filled with at least one first polymeric material surrounding the circuitry. Figures 10A-10D As shown, in the described example, the IO port is threaded. For example, the threaded IO port can advantageously enable the inline converter 605 to be (releasably) coupled to a connector or device.

[0106] Fig.11A , Fig. 11B , Fig. 11C , Fig.11D and Fig.12 An exemplary in-line converter and the associated exemplary electrical and logical architecture of the exemplary in-line converter are depicted. As an illustrative example, the length of the entire converter can be, for example, 57.8 mm. The length of the body 1105 of the converter can be, for example, 27.9 mm. The diameter of the converter can be, for example, 15 mm. Fig. 11C The connector 1110 shown may be, for example, M12 x 1-6G. Fig.11D The connector 1115 shown may be, for example, M12 x 1-6H. By way of example and not limitation, various embodiments may provide other sizes and / or size ratios.

[0107] In the illustrative scenario 1200, the online converter 605 is configured to receive a 2-wire or 3-wire input (e.g., analog). The online converter 605 is configured to be coupled to a Modbus network via RS485. The online converter 605 shown is configured according to the schematic diagram 1201. For example, the input 1205 of the converter module 1210 (e.g., including part or all of the circuit 605A) can be configured to receive an input loop (e.g., V+ and V-, respectively) on pins 1 and 2. Pins 3 and 4 can, for example, provide power and / or reference voltages (as shown). In the example shown, the output 1215 is configured as a 10-30VDC output on pin 1 and is configured as RS485 output V+ and V- on pins 2 and 3, respectively. Pin 3 is configured as a (voltage reference) ground.

[0108] Furthermore, in the illustrative scenario 1200, the online converter 605 may be configured with (digital) registers, as shown in table 1202. The registers may be configured, for example, on one or more data storage devices (e.g., inside the online converter 605). The first register (40001) may be configured as an analog data output. The second register (40002) may be configured as an alarm state (e.g., with a binary output). The third register (40003) may be configured as a discrete value. The discrete value may correspond to the state of the instruction program currently being executed (e.g., no error, below a predetermined threshold, above a predetermined threshold).

[0109] In various embodiments, one or more additional registers (e.g., register 615) may be configured, for example, according to a particular application. For example, an additional register may hold a temperature value. For example, a register may be configured to hold a pressure value. In some implementations, a register may be configured to hold at least one of a voltage value (e.g., 0-10V), a DC current value (e.g., 4-20mA), and / or an AC current value (e.g., 0-20 or 0-150mA).

[0110] While some implementations may provide analog input to Modbus conversion to work with the RX90, some embodiments may provide further functionality in accordance with embodiments of the present description.

[0111] Various embodiments may advantageously provide a connector combination configured to accept various input types, such as analog (0-10VDC, 4-20mA, transformer AC, temperature / thermistor). The connector may generate signals, for example, according to the Modbus (RS-485) protocol. Various embodiments may generate signals according to the I / O Link protocol.

[0112] Fig.13An exemplary sensing circuit that can be used in an exemplary in-line converter (e.g., in-line converter 605) is depicted. The sensing circuit 1300 includes a first resistor 1305 (having a resistance R1) coupled between a reference voltage (Vref) and an input voltage (Vin). The sensing circuit 1300 includes a second resistor 1310 (having a resistance Rt) coupled between Vin and a reference point (labeled "GND"). As shown, Vref, Vin, and GND are all coupled to an analog-to-digital converter (ADC 1315).

[0113] In an exemplary embodiment, for example, Rt can be determined according to Equation 1:

[0114] Equation 1:

[0115] The value of Rt can correspond to a measured (physical) metric. For example, Rt can correspond to a thermistor resistance (e.g., a signal corresponding to temperature). The online sensor connector can be configured to apply a predetermined (e.g., preconfigured, preloaded) curve (e.g., a calibration curve) to determine the temperature from Rt. In some embodiments, a signal corresponding to Rt can be generated and transmitted to an upstream device and / or another edge device (e.g., for processing into a temperature value for acting according to a predetermined rule). In some embodiments, Vin, Vref, and / or GND in Equation 1 can, for example, correspond to ADC counts generated in response to actual Vin, Vref, and / or GND signals.

[0116] Such an embodiment may, for example, allow self-calibration of multiple ADC options. For example, a (precise) voltage divider (e.g. Fig.13 ). Thus, each measurement cycle may advantageously allow for self-calibration of the ADC channel by reading the ADC counts of a voltage divider (Vref, Vdiv, GND) with the same ADC settings / parameters. From these ADC counts, and knowing the voltage divider value (e.g., corresponding to R1), the offset of the ADC with the same settings may be found. Thus, various embodiments may advantageously allow for dynamic and / or self-calibration without the need for a calibration step. Such embodiments may advantageously provide a "plug and play" functionality.

[0117] In some embodiments, a "universal" sensor connector may be configured such that a single device may be used to receive dual voltages and / or currents, and / or connect a thermistor and / or a current transformer.

[0118] Such an embodiment may, for example, include multiple circuits with multiple switches. Each (each group of) switches may be connected to a different pin of a processor in a connector. The switches may, for example, be configured (e.g., dynamically, in the field, pre-configured) to connect the circuit to the processor corresponding to the desired configuration.

[0119] As an illustrative example, a user may select a configuration associated with a thermistor input (e.g., a universal sensor connector using a thermistor). For example, a corresponding resistor may be operated (e.g., held low) to produce a voltage divider at one end. The voltage of the input may be read using the voltage divider. The voltage supplied to the voltage divider may be known. Thus, the voltage "seen" by the thermistor (e.g., corresponding to a temperature) may be determined. For example, a corresponding temperature may be produced.

[0120] As another illustrative example, a voltage reading configuration may be selected. A circuit element may be operated to activate a voltage divider. For example, a resistor may be pulled high (e.g., the same resistor). A voltage on a pin (e.g., corresponding to the same pin of the voltage divider) may be read.

[0121] Thus, various embodiments may advantageously provide multiple circuits in parallel with one or more pins. Different circuits may be selectively activated based on a configuration (e.g., defining the state of a connector). Various configurations may be adapted to (dynamically) convert voltage and / or current inputs into various (desired, predetermined) outputs. Thus, various embodiments may, for example, read a voltage and convert it into a temperature, current, or "through" voltage value.

[0122] Various embodiments can advantageously provide a configurable sensor connector. By allowing a single item code to be used for multiple operations, various embodiments can advantageously reduce the number of item codes (e.g., SKUs) that an entity (e.g., a factory, a warehouse) must maintain. Various embodiments can advantageously reduce device obsolescence. For example, if a temperature sensing configuration is no longer required, a "universal" connector can advantageously be reconfigured to a desired application (e.g., current sensing).

[0123] In some embodiments, the connector can be dynamically operated between multiple configurations. For example, by way of example and not limitation, the connector can be operated between a voltage reading mode and a current conversion mode. For example, the connector can be configured to (internally) alternate between modes. In some embodiments, the connector can be dynamically configured externally (e.g., by a connected controller such as a control hub 165). In an illustrative example, the controller can configure the connector to current mode. If the detected current exceeds the current sensing range of the connector, the controller can operate the connector to voltage mode and determine the current voltage read by the controller. Such embodiments can, for example, advantageously enhance troubleshooting, fault handling, and / or data collection.

[0124] In some embodiments, a multi-pin sensor connector may, for example, simultaneously provide power and simultaneously read data from a sensor. Such embodiments may include a (sub)circuit configured to provide power on one pin and a (sub)circuit configured to read data on another pin. Some such embodiments may, for example, have at least 3 pins. Some embodiments may, for example, have 4 pins. Some embodiments may have more than 4 pins.

[0125] In some embodiments, the sensor connector can be configured, for example, to generate a signal corresponding to a voltage, current, and / or resistance value based on the ADC value. For example, such an embodiment can include a known reference circuit. The ADC slope and offset calibration can be predetermined (e.g., stored, dynamically determined during calibration). A known ADC slope and / or offset can be applied to the ADC count to generate a voltage, current, and / or resistance output signal.

[0126] Fig.14A and Fig. 14B An exemplary temperature and humidity sensor is depicted. The sensor assembly 1400 includes a sensor body 1405. A sensor shroud 1410 is (releasably) coupled to a distal end of the sensor body 1405. A disassembly mode 1401 of the sensor assembly 1400 is described. The sensor assembly 1400 includes a sensor element 1415 (e.g., configured to respond to temperature and / or humidity in a predictable manner). The sensor shroud 1410 can be threadedly coupled to the sensor body 1405, for example, via threads 1420 (internal threads can be provided on the sensor shroud 1410). In some embodiments, the sensor assembly 1400 can be coupled to a cable and / or connector at a proximal end. The sensor assembly 1400 can be configured to generate and / or receive signals at an output port 1425 according to a predetermined protocol (e.g., IO-Link, Modbus).

[0127] Fig.15A , Fig. 15B , Fig.16A , Fig. 16B , Fig. 16C and Fig.16D An exemplary communication hub is depicted. Figure 15A-15B Depicted are an illustrative communication hub 155 and an illustrative dual-port communication hub 156. For example, the dual-port communication hub 156 may advantageously provide reduced cost and / or reduced size compared to the communication hub 155.

[0128] Figures 16A-16DThe communication hub 155 and the dual-port communication hub 156 are compared to the illustrative IO-link host 1605 and the illustrative IO-link block 1610. In various embodiments, the communication hub 155 and / or the dual-port communication hub 156 can provide a surface-mounted form factor that is configured so that the cable is led out from a narrow (e.g., narrowest) surface (e.g., an "edge" surface) of the hub. Such an embodiment can, for example, advantageously reduce the space used for wiring the hub. For example, the communication hub 155 can be advantageously fixed on the upper surface 1615 and / or the corresponding bottom surface. In the described example, the cable can be led out from one or more edge surfaces 1616. The dual-port communication hub 156 can, for example, be advantageously fixed on the upper surface 1620 and / or the corresponding bottom surface. In the described example, the cable can be led out from one or more edge surfaces 1621. Such an embodiment can advantageously reduce space by keeping the cable in a linear configuration. Various embodiments can advantageously reduce bending of the cable (e.g., and corresponding interference, grabbing, breaking). Various embodiments can advantageously provide a form factor having a thickness that is of the same order of magnitude as the cable and / or connector width (e.g., corresponding to the width of an edge surface such as one or more edge surfaces 1616 and / or one or more edge surfaces 1621). For example, as shown, the thickness of the communication hub 155 and the dual-port communication hub 156 can be substantially the same as the (outer) diameter of the associated connector (e.g., an M12 connector). Various embodiments can advantageously provide a hub that is easy to install. Various embodiments can advantageously provide a low profile hub. Various embodiments can provide a communication and / or control hub with a small form factor.

[0129] In the described example, the communication hub 155 and the dual-port communication hub 156 are configured as IO-Link hubs. For example, the communication hub 155 can provide four IO-Link ports (labeled 0, 1, 2, and 3). The communication hub 155 can be coupled to an upstream device (e.g., an IO-Link host) via a fifth port. For example, the four IO-Link ports can be master ports. For example, the communication hub 155 can be configured to operate as a master device for up to four downstream devices (e.g., sensors, slave hubs, indicators).

[0130] The dual-port communication hub 156 can, for example, provide two IO-Link ports (labeled "Port 0" and "Port 1"). The dual-port communication hub 156 can be coupled to an upstream device (e.g., an IO-Link master) via a third port, for example. The two IO-Link ports can be, for example, master ports. For example, the dual-port communication hub 156 can be configured to operate as a master device for up to two downstream devices.

[0131] For example, multiple communication hubs with different numbers of ports may provide cost and / or size flexibility depending on the needs and / or plans of the configurator.

[0132] In some embodiments, the fifth port of the communication hub 155 and / or the third port of the dual-port communication hub 156 can, for example, send signals (e.g., corresponding to data) and / or receive signals (e.g., corresponding to commands, configurations, data) from an upstream hub and / or controller (e.g., control hub 165).

[0133] For example, various embodiments may advantageously allow "smart" signals to be brought onto public networks. Various embodiments may advantageously create a DCCS using open communication protocols. Such embodiments may, for example, allow proprietary and / or other protocol-based devices to be integrated into the DCCS.

[0134] Fig.17 An exemplary dynamically configurable control hub (DCCH) is depicted. The control hub 165 includes a plurality of downstream ports 1705. A set of indicators 1710 are provided to correspond to each of the plurality of downstream ports 1705. For example, the body of the control hub 165 can be overmolded around the internal circuitry. The indicators 1710 can, for example, correspond to LEDs overmolded by at least partially translucent material. In some embodiments, the LEDs can, for example, be straight (e.g., vs. tilted). For example, surface mounted markings can advantageously provide easy viewing outside of the cable plane.

[0135] Multiple downstream ports 1705 can be configured to be connected to equipment via Modbus protocol, for example. In the described example, multiple downstream ports 1705 include four Modbus ports (labeled as 1, 2, 3 and 4). Control hub 165 also includes port 1715 and port 1720. For example, port 1715 and / or port 1720 can each be configured to communicate with Modbus protocol. In certain embodiments, port 1715 and / or port 1720 can be connected logically and / or physically. For example, port 1715 and port 1720 can, for example, collaborate as a single through port. In some embodiments, by way of example and not limitation, ports 1715, 1720 can be continuously coupled to identical internal master or slave connection point.

[0136] One or more of port 1715, port 1720, and / or multiple downstream ports 1705 may be configurable. For example, port 1715 and port 1720 may be configured as a single pass-through port (e.g., port 4). For example, ports 0-4 may be configured (individually, independently) as (Modbus) master ports. For example, ports 0-4 may be configured (individually, independently) as (Modbus) slave ports. In some embodiments, at least one of multiple downstream ports 1705 may be coupled to a downstream port (e.g., a sensor, an indicator, a hub). Port 1715 and / or port 1720 may, for example, be coupled to a transceiver (e.g., connected to cloud network 175, connected to a controller). In the described example, control hub 165 may be configured with up to 5 Modbus master connections. The connector may, for example (as shown), be configured to be physically coupled via an M12 connector.

[0137] In various embodiments, port 1715 and port 1720 can be configured in a pass-through mode. For example, such an embodiment can allow control hub 165 to be "daisy-chained" with other hubs (e.g., other control hub 165 units). For example, such an embodiment can allow control hub 165 to be coupled to a Modbus trunk. For example, daisy chaining can advantageously reduce required wiring. For example, the form factor can allow in-line coupling in the trunk (e.g., without bending the cable).

[0138] The control hub 165 includes a port 1725. For example, the port 1725 can be configured to communicate using the Modbus TCP protocol. The port 1725 can be configured to communicate with one or more external devices using one or more protocols. For example, the port 1725 can be configured to communicate according to Ethernet / IP TM For example, port 1725 can be configured to communicate according to Protocol for communication. For example, port 1725 can be configured to communicate according to the MQTT protocol. In some embodiments, for example, port 1725 can be configured as an Ethernet port using an M12 D-coded Ethernet connection. For example, port 1725 can be configured as a 100 Mbps (nominal) connection.

[0139] In some embodiments, for example, port 1725 and / or port 1720 can be configured to act as a configuration and / or discovery port. In this example, control hub 165 includes control device 1730. Control device 1730 can be configured to automatically and independently configure each of ports 1705, 1715, 1720, 1725 to operate as a primary port, an auxiliary port, or a pass-through port. For example, 1730 can associate a communication protocol (e.g., Modbus, TCP / IP, TCP / IP) at each port 1705, 1715, 1720, 1725 based on an identification. ). refer to Figure 18-19 Some exemplary embodiments for configuring control hub 165 using control device 1730 are described.

[0140] In some embodiments, the control hub 165 can communicate with the network (e.g., master device, peer device, slave device) via port 1720 and / or port 1725. For example, the control hub 165 can respond to discovery requests and / or perform network discovery operations (e.g., refer to Figure 2 Identification step 205 described above).

[0141] Fig.18 and Fig.19 Describes an exemplary block diagram of an exemplary DCCH. Block diagram 1800 depicts a block-level circuit schematic diagram of an exemplary control hub 165 by way of example and not limitation. In the described example, each connection port 1805 may include a separate (e.g., separate, independent) Modbus master / slave control. In some embodiments, programmability is provided for each connection port 1805. Baud rate and / or parity settings may, for example, be individually selectable (e.g., predetermined, via a configuration profile, dynamic). Separate timing and packet timing may be provided for each Modbus connection at the connection port 1805. One or more connection ports 1805 may be configured as a two-wire RS485 physical transceiver with power and ground at each connector.

[0142] In the depicted example, male M12 connection port 1810 can provide common power and ground to all M12 Modbus ports. For example, the male M12 connection can correspond to port 1720. As shown, the control hub 165 also includes a female M12 pass-through connection port 1815. For example, the control hub 165 can be configured so that some signals can be transmitted as "pass-through" via the control hub 165 so that multiple control hubs 165, communication hubs 155, and online converters 145 can be connected online. Reference Fig.19 Further details of various embodiments of the pass-through configuration of control hub 165 are discussed.

[0143] In the described example, the control hub 165 includes a processor 1820. For example, the processor 1820 can execute a predetermined rule (e.g., an action rule, a script) in response to a signal received from the connection port 1805. For example, in some embodiments, a configurator tool can be used to configure one or more rules. In this example, the processor 1820 can retrieve an industrial protocol 1825 (e.g., Modbus, TCP, EIP, Profinet protocol) to interpret the rule from the received signal. The rule can, for example, include reading from a port, writing to a port, applying an operation to a signal received from a port, or some combination thereof.

[0144] In this example, the control hub 165 includes a data storage 1830. For example, the processor 1820 can be configured to execute instructions stored in the data storage 1830. As shown, the data storage 1830 includes an identification rule set 1835 and a configuration rule set 1840. For example, the identification rules 1835 and 1840 can be programmed by a configuration tool connected to the control hub 165. In some embodiments, the processor 1820 can use the identification rule 1835 to identify the communication mode and communication protocol of each of the connection ports 1805, 1810, and 1815. For example, the identification rule 1835 can be configured to identify whether the connection port is a master port, a slave port, or a pass-through port. For example, the identification rule 1835 can be configured to identify the communication protocol of the connection port based on the received signal. In some embodiments, after identifying the communication mode and communication protocol of each of the connection ports 1805, 1810, 1815, the processor 1820 can associate the corresponding communication mode with each of the connection ports 1805, 1810, 1815 based on the configuration rule 1840. For example, the processor 1820 can associate one of the industrial protocols 1825 with the connection ports 1805, 1810, 1815.

[0145] Various embodiments may, for example, advantageously enable a user to send selected information to (predetermined, dynamically determined) edge devices and / or central devices (eg, controller, cloud system).

[0146] Fig.19 A block level schematic diagram of an exemplary control hub (e.g., control hub 165) is shown by way of example and not limitation. In the depicted example, controller 1905 includes processor 1820. Processor 1820 may, for example, include one or more processors. In the depicted example, processor 1820 is (e.g., logically) divided into at least interrupt thread 1911 and script thread 1912.

[0147] Processor 1820 is operably coupled to a plurality of ports. As shown, processor 1820 is operably coupled to four ports 1920. Processor 1820 is operably coupled to port 1925 and port 1930. As shown, port 1925 is operably coupled to port 1930. Processor 1820 is also operably coupled to port 1935.

[0148] In some embodiments, by way of example and not limitation, port 1920 may, for example, be publicly configured with reference to at least multiple downstream ports 1705. For example, port 1925 may be publicly configured with reference to at least port 1715. For example, port 1930 may be publicly configured with reference to at least port 1720. For example, port 1935 may be publicly configured with reference to at least port 1725.

[0149] In various embodiments, port 1925, port 1930, and / or any or each port 1920 may be read by an interrupt thread 1911 of the processor 1820. For example, port 1925, port 1930, and / or port 1920 may be logically (e.g., controllably, user programmably, independently) coupled to the interrupt thread 1911 (e.g., by connecting to pins controlled by the interrupt thread 1911) individually or in combination as shown. The signals received by the interrupt thread 1911 from the various ports may, for example, be converted into data stored in a memory module 1915. The memory module 1915 may be operably coupled to the processor 1820. The memory module 1915 may be accessed by both the interrupt thread 1911 and the script thread 1912 (e.g., through a common pin, through a dedicated pin). The memory module 1915 may, for example, include one or more instruction programs configured to be executed on the processor 1820.

[0150] For example, data read from each port can be stored in one or more registers 1916 of the memory module 1915. For example, one or more registers 1916 can each include a data storage unit for 16-bit data. For example, one or more registers 1916 can each include a data storage unit for 32-bit data. For example, one or more registers 1916 can be accessed via one or more ports. For example, one or more registers 1916 can be configured to be globally accessible via the processor 1820. For example, in response to a first signal read on a first port (e.g., in an illustrative temperature example, from a thermistor operably coupled to the first port), first data (as an illustrative example, temperature) can be generated and stored in one or more registers 1916. A second signal corresponding to the temperature can be generated based on the first data stored in one or more registers 1916 and sent via a second port. For example, the second signal can correspond to the temperature in the illustrative temperature example (e.g., displayed on a human-readable display). In some embodiments, the signal can be transmitted to an external controller, a cloud system, a collection device, a monitoring device, or some combination thereof via Ethernet (e.g., via port 1935).

[0151] The memory module 1915 also includes a configuration profile 1917. In various embodiments, the configuration profile 1917 may store one or more profiles corresponding to the configuration of the controller 1905. The configuration profile 1917 may, for example, store one or more profiles corresponding to the configuration associated with one or more ports. The configuration profile 1917 may, for example, store one or more profiles corresponding to the configuration associated with the processor 1820 (e.g., interrupt thread 1911, script thread 1912). For example, the configuration profile 1917 may determine the master configuration or slave configuration of the port (e.g., five ports 1920, port 1925, port 1930). The configuration profile may, for example, determine the state of the programming engine (e.g., enabled, disabled, configuration in an enabled state). The configuration profile may, for example, determine the protocol module to be applied to one or more ports. The configuration profile may, for example, determine the "pass-through" configuration of port 1925 and / or port 1930. For example, a pass-through configuration may advantageously allow more than one "in-line" connection in control hub 165 to save connection equipment and reduce configuration complexity.

[0152] The memory module 1915 includes a programming engine 1918. The programming engine may, for example, include one or more instruction programs configured to be executed on the processor 1820. The engine 1918 may, for example, be executed (primarily) by the script thread 1912. The engine 1918 may, for example, be configured to operate on data in one or more registers 1916. The engine 1918 may, for example, operate on one or more registers 1916 based on a configuration profile 1917. In some embodiments, the engine 1918 may, for example, generate a signal to cause an interrupt thread 1911 to interrupt an operation related to one or more ports (e.g., a read operation, a write operation, a send operation).

[0153] The memory module 1915 includes a protocol module 1919. For example, the module 1919 may include one or more protocol profiles defining protocols associated with one or more ports. The protocol profile may, for example, determine operations performed by the interrupt thread 1911 and / or the script thread 1912. For example, in some embodiments, the protocol profile may be associated with a Modbus (e.g., Modbus TCP) protocol. The protocol profile may, for example, define operations and / or parameters associated with a master mode of a port. The protocol profile may, for example, define operations and / or parameters associated with a slave mode of a port. The protocol profile may, for example, define operations and / or parameters associated with an Ethernet protocol. The protocol profile may, for example, define operations and / or parameters associated with a TCP / IP protocol. Operations and / or parameters associated with the protocol. A protocol profile may, for example, define operations and / or parameters associated with the MQTT protocol.

[0154] In various embodiments, for example, ports (e.g., five ports 1920, port 1925, port 1930) can be configured as master and / or slave. In some embodiments, the master / slave configuration can correspond to a master or slave mode defined by the Modbus protocol, for example. For example, the protocol module 1919 can use the identification rules 1835 and configuration rules 1840 stored in the data storage 1830 to configure the ports.

[0155] For example, a port configured as a host may initiate a read operation (e.g., controlled by interrupt thread 1911) on a connected device (e.g., a sensor, a hub, a controller, an indicator, an interface). For example, data may be stored in response to a signal generated during a read operation. The data may be stored by interrupt thread 1911 in one or more registers 1916 (e.g., global local registers). In various embodiments, interrupt thread 1911 may access one or more registers 1916 on behalf of any other port. In various embodiments, 1912 may access one or more registers 1916 (e.g., according to the operation of engine 1918).

[0156] For example, if a port is a master port, it can read a temperature sensor connected to the port. Reading a temperature sensor can, for example, include sending a signal to the temperature sensor (e.g., via a Modbus protocol). The signal can be transmitted to the temperature sensor via one or more intermediate devices (e.g., a communication hub, a control hub, an online connector, and / or a converter). The signal can induce the temperature sensor and / or related devices to generate and send a response signal corresponding to the temperature to the port. The corresponding data signal can be generated by the interrupt thread 1911 and stored locally in a global register (one or more registers 1916). A corresponding signal can be generated (e.g., by a script thread 1912, e.g., according to an engine 1918, a configuration profile 1917, and / or a module 1919). The corresponding signal can, for example, be sent to the interrupt thread 1911. The interrupt thread 1911 can, for example, responsively generate a transmission signal that can be written out (e.g., sent) to a second connected device via another port. For example, the second connected device may need to receive a temperature and / or a temperature-based signal (e.g., a command to start a fan based on a temperature above a (predetermined) threshold).

[0157] Various embodiments may advantageously provide a single memory pool accessible by multiple ports. Thus, various embodiments may provide multiple (Modbus) master ports and / or slave ports configured to share received data and / or data generated in response to received data with devices connected to the same master port and / or other master ports and / or slave ports. Various embodiments may be configured to share received data and / or data generated in response to received data with devices connected to non-Modbus ports (e.g., Ethernet).

[0158] Various embodiments can advantageously receive and / or send data from multiple devices (e.g., up to 247 Modbus slave devices per Modbus master port). In some embodiments, for example, controller 1905 can be operably coupled to 247 slave devices per master port * 5 ports (e.g., 5 ports 1920, port 1925 / port 1930) = 1482 connected devices. In some embodiments, for example (e.g., at least reference Fig.18 ), the control hub 165 can be operably coupled to each master port 247 slave devices * 5 ports = 1235 connected devices. For example, data can be advantageously compacted (e.g., via branching, hierarchical wiring of the hub) and efficiently shared between devices without the need for separate cables to a central controller.

[0159] In some embodiments, one or more ports may be connected to a single device. For example, a user may not want to define a separate address for each slave device. For example, a user may have 5 devices (e.g., in the illustrative example, 3 sensors, 1 actuator, and 1 indicator). Each device may be preconfigured with a (Modbus) address. The user may couple each device to its own port on the control hub 165. For example, each port may be configured as a master port. The control hub 165 may be configured (e.g., via the engine 1918) to automatically determine the preconfigured address of the (single) connected device. A (predetermined) program (e.g., a user rule profile 1918a of the memory module 1915, at least according to the profile 1918a configured to be executed by the script thread 1912 according to the engine 1918) may reference the device by port rather than by (Modbus) device address. For example, such an embodiment may advantageously provide a "plug and play" implementation (e.g., avoiding the user from configuring addresses for each connected device).

[0160] The profile 1918a may, for example, include one or more user-configured rule sets and / or scripts. For example, the engine 1918 may include a rule-based engine. The rule-based engine may, for example, implement operations based on ports and / or predetermined operators (e.g., arithmetic, Boolean, logical, read / write). For example, a user role profile for a rule-based engine may be programmed in a spreadsheet-style interface.

[0161] In an illustrative example, a user rule profile (configured to be implemented by script thread 1912 according to engine 1918) can be configured to read from a temperature sensor on a first port (e.g., read by interrupt thread 1911 to one or more registers 1916), and if the temperature is greater than a predetermined threshold (e.g., 80° F.), set a light value in another register. The user rule profile can, for example, further cause the light value to be written (e.g., by interrupt thread 1911) to a tower light connected to a second port.

[0162] In another illustrative example, the user rule profile can be configured to read and / or write data from a port to a (predetermined) register (in one or more registers 1916) based on a rule-based engine in engine 1918. Another user rule profile can be implemented as a script, for example, which is configured to be executed by a script thread 1912 according to the second engine 1918. For example, the second engine can be a script engine. As an example and not a limitation, the script engine can include a (micro) Python script engine. For example, a user can configure a script (defined in the user rule profile) to read and / or write a register from a register based on a rule applied by a rule-based engine. In certain embodiments, a user can configure a script to interact directly with a port (for example, via an interrupt thread 1911) without and / or in addition to a rule-based engine.

[0163] Thus, various embodiments can advantageously provide user-configurable (e.g., field-configurable, remotely-configurable, dynamically-configurable) edge processing of edge device data. In some embodiments, user rule profiles, registers, and / or configuration profiles can advantageously be stored and / or retrieved via port 1935 (e.g., via an Ethernet-based system, such as a computer, controller, cloud system), port 1925, port 1930, or some combination thereof.

[0164] In an illustrative example, an edge device can be configured to detect a vehicle in a parking spot (e.g., connected via a first port). The time at which the vehicle is detected can be stored in a register. For example, a user input (e.g., requesting a charging time) can be received on a second port. (e.g., according to a user rule profile). The time can be retrieved and compared to the time at which the request was received (e.g., also stored in a register), and a fee can be calculated, for example (e.g., locally, remotely). For example, the fee can be presented to a user (e.g., a driver of the vehicle) via a second edge device (e.g., connected to a second port).

[0165] Various embodiments may advantageously provide multiple master ports and / or slave ports that operate in parallel (e.g., read / write data). Each port may advantageously be associated with a dedicated connection to processor 1820. Each port may advantageously be associated with dedicated logic (e.g., rules, profiles, parameters).

[0166] The multiple threads of processor 1820 can, for example, advantageously provide actual (simultaneous) parallel operation of ports. For example, the Modbus protocol may take several milliseconds to complete (e.g., read, write). The controller interface (e.g., retrieving and / or storing data to one or more registers 1916 via interrupt thread 1911) may take several microseconds. Therefore, interrupt thread 1911 can advantageously serve multiple ports running simultaneously (e.g., in a "round-robin" manner, according to interrupt logic, as a direct memory access controller). For example, each port can have a dedicated circuit (e.g., a chip). For example, a dedicated port circuit can be configured to execute a command in response to a signal from interrupt thread 1911.

[0167] As an example, the interrupt thread 1911 may issue a command to the master port to write 10 registers to the connected edge device. For example, the (input-output (IO)) port may take 50 milliseconds to complete the operation of the command. However, the processor 1820 may only take 10 microseconds to access one or more registers 1916 and generate a signal and send it to the master port.

[0168] In some embodiments, port 1925 and port 1930 can be physically connected. For example, port 1925 and port 1930 can be configured as RS485 connections and can be physically configured as differential pair signaling. The electrically continuous conductor can, for example, connect the same twisted pair in port 1925 and port 1930. Therefore, such an embodiment can advantageously act as a physical through connector. In some embodiments, the through connector can advantageously access one or more registers 1916 (e.g., via interrupt thread 1911).

[0169] Fig. 20 , Fig.21 , Fig. 22 , Fig.23 and Fig.24 Depicted is an exemplary DCCH deployed in an illustrative use case scenario.

[0170] System 2000( Fig. 20 ) are deployed in an illustrative use case scenario. For example, the control hub 165 is connected to two communication hubs 155 (a first hub 155a and a second hub 155b) simultaneously. In the first scenario 2005, the first hub 155a is connected to an edge device. In the first scenario 2005, the component 2010 can be monitored by four optical sensors 2015. The first hub 155a provides a single communication cable between the four optical sensors 2015 and the control hub 165. The control hub 165 can, for example, provide edge processing and / or can communicate with remote devices (e.g., a cloud network, a remote controller, a central controller).

[0171] In the second scenario 2020, the second hub 155b is connected to the edge device. In the second scenario 2020, the part 2025 can be monitored by four optical sensors 2030. The second hub 155b can provide a single communication cable between the control hub 165 and the four optical sensors 2030.

[0172] In an illustrative example, system 2000 may correspond, for example, to verifying part in place and trending assembly fixture quality over time. Multiple position and / or distance measurement sensors may be configured to verify part in place checks. Curves that vary over time may be developed. For example, the curves may be used to determine quality assurance of assembly fixtures.

[0173] For example, by monitoring multiple stations with a single control hub 165, cabling can be advantageously minimized.

[0174] Existing sensor signals may be converted into a desired communication protocol (eg, IO-Link, Modbus), for example, using a converter (eg, in-line converter 145 , not shown).

[0175] exist Fig.21 In the illustrative example shown, scenario 2100 may correspond, for example, to a programmable controller configured to calculate thickness measurements from a plurality of devices. Signals (e.g., Modbus signals) may be collected from a plurality of distance measurement devices (e.g., edge devices 105). Scenario 2105 depicts a corrugated plate 2110 monitored by an optical distance sensor. Scenario 2115 depicts a solid plate 2120 monitored by an optical distance sensor.

[0176] The edge device 105 can be coupled to the control hub 165 (as shown), for example, via the online converter 145. The control hub 165 can be configured with action rules (e.g., based on at least reference Fig.19 Disclosed profile 1918a), the action rule is configured to calculate a thickness measurement value.

[0177] In various embodiments disclosed herein, available (predetermined) action rules (e.g., for inclusion in a rule-based profile 1918a to be implemented by the rule-based engine 1918) may include, by way of example and not limitation, threshold parameter timers (e.g., minimum on / off times, and / or recording options), predetermined rules (e.g., arithmetic operators, bitwise operators), control logic (e.g., logical operators; SR, T, D and / or JK triggers), trend parameters (e.g., multiple averaging filters) and / or tracking parameters (e.g., counts, on / off times).

[0178] exist Fig. 22In the illustrative example shown, the system 2200 can, for example, be configured to integrate redundancy and logic for a (critical) tank level application. Various edge devices 105 (e.g., pumps, discrete tank sensors, analog tank sensors, indicators, discrete override switches) are coupled to the control hub 165 via various multi-drop connectors 135 and / or in-line converters 145. The edge devices 105 can be configured to monitor and / or respond to the level in the tank 2205. Redundant pump controls and / or logic rules can be programmed directly into the control hub 165 (e.g., via profile 1918a).

[0179] The control hub 165 can, for example, visualize incremental changes in precise applications (e.g., via edge devices 105, via remote devices such as direct connections, and / or via a (cloud) network). For example, these changes can be advantageously visualized without the need for emulating PLC cards, shielded cables, and / or programming. Existing edge devices 105 can advantageously be coupled to the control hub 165 using a common protocol via an in-line converter 145.

[0180] In the illustrative example, the system 2300 ( Fig.23 ) can be configured, for example, to minimize analog inputs for condition monitoring and predictive maintenance of assets in the illustrative environment 2301. For example, various edge devices (e.g., tank level sensors, temperature sensors, pressure sensors, vibration sensors) can be coupled to the control hub 165.

[0181] For example, the control hub 165 can advantageously enable a user to monitor the condition of an asset and / or trend data over time to gain insight into a failure before it occurs. The control hub 165 can, for example, minimize analog input card requirements on the PLC by utilizing Modbus. For example, four sensors can be advantageously coupled to the control hub 165 shown (e.g., without separate configuration of sensors). As an example and not limitation, the sensors can, for example, include temperature and vibration sensors (e.g., configured to advantageously enable rapid intervention to avoid downtime). The sensors can include, for example, tank level status (e.g., configured to advantageously avoid material overflow and / or depletion). The sensors can, for example, include current transducers (e.g., configured to monitor current consumption and / or trends over time). The sensors can, for example, include (infrared) temperature sensors (e.g., configured to advantageously provide non-contact temperature measurement). The sensors can, for example, include thermistor probes (e.g., configured to advantageously determine pre-processing and / or post-processing temperature measurements).

[0182] exist Fig.24In the illustrative example shown, by way of example and not limitation, the system 2400 can be configured to rapidly deploy a Modbus slave device to Ethernet / IP, Modbus TCP, and / or network. For example, the control hub 165 can be provided with five independent Modbus master ports. For example, the ports can advantageously increase simplicity and / or reduce deployment time of co-located assets. For example, in the illustrated control hub 165, up to five Modbus slave devices can advantageously be connected out of the box without having to manually assign slave addresses to the connected devices.

[0183] System 2400 includes five motors 2410. Each motor 2410 is equipped with a sensor 2415 (e.g., a vibration sensor, a temperature sensor, a current sensor). Each sensor 2415 can be individually connected to the control hub 165. The (predetermined) profile 1918a can be loaded onto the control hub 165 (e.g., via a port such as port 1935, port 1725).

[0184] Fig.25 A flow chart of an exemplary signal processing method 2500 for an exemplary DCCH is depicted. For example, the control hub 165 may execute the method 2500 to process an incoming signal. For example, the communication hub 155 may execute the method 2500 to process an incoming signal. In this example, the method 2500 begins when a signal is received at a connection port at step 2505. For example, one of the ports 1920, 1925, 1930, 1935 may receive a signal from one of the edge devices 105. For example, one of the ports 1920, 1925, 1930, 1935 may receive a signal from a remote control device via the remote communication gateway 170.

[0185] In step 2510, a configuration profile associated with the connection port may be retrieved. For example, the processor 1820 may retrieve the configuration profile 1917 from the memory module 1915. In step 2515, an operation is identified based on the configuration profile. For example, the processor 1820 may identify the operation based on the configuration profile and rules defined in the programming engine 1918. In decision point 2520, it is determined whether the connection port is a pass-through port. For example, based on the configuration profile 1917 associated with the connection port, the connection port may be defined as a pass-through port. If it is determined that the connection port is a pass-through port, then in step 2525, the received signal is passed to the output port defined by the configuration profile, and the method 2500 ends. For example, the configuration profile 1917 may define the port 1930 as a pass-through port, and the signal received at the port 1930 may be passed to the port 1925.

[0186] If it is determined at decision point 2520 that the connection port is not a pass-through port, then it is determined at decision point 2530 whether the identified operation is a write operation. If the identified operation is a write operation, then at step 2535, the data corresponding to the received signal is stored in a shared data register defined by the configuration profile, and the method 2500 ends. For example, the configuration profile 1917 may define addresses in one or more registers 1916 to store data represented by the received signal.

[0187] If it is determined at decision point 2530 that the identified operation is not a write operation, then it is determined whether the identified operation is a read operation at decision point 2540. If the identified operation is a read operation, then a shared data register associated with the input signal is identified at step 2545. For example, the processor 1820 may identify the address of the associated shared data register based on the connection port, the received signal, and the configuration profile 1917. Next, at step 2550, an output signal is generated at the output port based on the data stored in the identified shared data register, and the method 2500 ends.

[0188] If it is determined at decision point 2540 that the identified operation is not a read operation, then it is determined at decision point 2555 whether the identified operation is a configuration operation. If the identified operation is not a configuration operation, then method 2500 ends. If the identified operation is a configuration operation, then exemplary configuration method 2600 as described below is performed.

[0189] Fig.26 A flow chart of an exemplary DCCH connection port reconfiguration method 2600 is depicted. In some embodiments, the method 2600 may refer to Fig.25 Executed after decision point 2555. In some implementations, method 2600 may be independently executed when a DCCH receives a reconfiguration signal to configure a configuration profile of one or more ports (1920, 1925, 1930, 1935).

[0190] When it is determined that the connection port is to be reconfigured, the method 2600 starts at step 2605. For example, the processor 1820 can determine one of the ports 1920, 1925, 1930, 1935 to be reconfigured based on the received signal. In step 2610, the first and second predetermined rule sets for identifying the communication profile of the connection port based on the received signal are retrieved. In step 2615, the operation mode of the connection port is identified based on the first predetermined rule set. For example, the processor 1820 can retrieve the identification rule 1835 to identify the communication profile based on the received signal. In step 2620, the communication protocol (e.g., Modbus, IO-Link) of the connection port is identified based on the first predetermined rule set. For example, the processor 1820 can identify the operation mode (e.g., master port, slave port, pass-through port) and the communication protocol (e.g., Modbus, analog, discrete) based on the configuration rule 1840. In step 2625, a configuration profile is generated based on the operation mode and the communication protocol. The configuration profile can be associated with a physical port, for example. At step 2630, the preconfigured virtual address is associated with the device address associated with the received signal. For example, the processor 1820 may identify the device address based on the received signal. The processor 1820 may, for example, associate the virtual address of one of the shared data registers with the device address so that a device (e.g., an edge device) associated with the device address may be advantageously referenced by the virtual address.

[0191] In step 2635, the association is stored in the configuration profile associated with the connection port, and method 2600 ends. For example, processor 1820 may update configuration profile 1917 associated with the connection port.

[0192] Fig. 27 A flow chart of an exemplary configuration method 2700 of an exemplary DCCH is depicted. For example, a user may use the method 2700 to set up a control hub 165 in the system 100. In this example, the method 2700 begins when a configuration profile is selected at a first user interface for a DCCH to be installed in step 2705. For example, a configuration profile may be selected based on a network protocol interface for each connection port of the control hub 165.

[0193] In step 2710, one or more rule-based engines are configured to implement operations on the DCCH in the second user interface. For example, a user can configure one or more rule-based engines 1918. For example, the operations can include threshold parameter timers (e.g., minimum on / off times and / or logging options), predetermined rules (e.g., arithmetic operators, bitwise operators), control logic (e.g., logical operators; SR, T, D, and / or JK triggers), trend parameters (e.g., multiple averaging filters), and / or tracking parameters (e.g., counts, on / off times). For example, the operations can include activating and / or deactivating edge devices (e.g., IO-link tower lights 120).

[0194] At decision point 2715, a determination is made as to whether an additional rule-based engine is to be configured (e.g., at another port, or operation). If an additional rule-based engine is to be configured, step 2710 is repeated. If an additional rule-based engine is not to be configured, at step 2720, the rule-based engine is compiled into a user rule profile (e.g., user rule profile 1918a). Next, at step 2725, the configuration profile and the user rule profile are saved to predetermined data registers, and method 2700 ends. In various embodiments, advantageously, when the control hub 165 is connected to a new device, user intervention may not be necessary after the control hub 165 automatically identifies the configuration profile of the newly connected device.

[0195] Fig.28 A flow chart of an exemplary write method for an exemplary DCCH is depicted. By way of example and not limitation, method 2800 may be called when step 2535 in method 2500 is being executed. In this example, method 2800 begins when a device address is identified in step 2805. For example, the device address may be identified based on a received input signal. For example, the device address may correspond to an edge device that transmits the input signal. Next, in step 2810, a virtual address is determined based on a connection port corresponding to the device address.

[0196] In decision point 2815, it is determined whether the virtual address is an internal address. For example, the virtual address may reference an internal device within system 100. In other examples, the virtual address may reference an external device. For example, the external device may communicate via remote communication gateway 170. If it is determined that the virtual address is an internal address, then at step 2820, the data is stored in a shared data register at the virtual address, and method 2800 ends. If it is determined that the virtual address is not an internal address, then at step 2825, the data is sent to the external device based on the virtual address, and method 2800 ends.

[0197] In various embodiments, the devices of the system 100 (e.g., edge devices 105, online converters 145, communication hubs 155, control hubs 165, wireless communication devices 160, and remote communication gateways 170) can be addressed by virtual addresses. In some examples, the user rule engine 1918 can reference devices based on virtual addresses. For example, a user can advantageously implement the engine 1918 without specifying device addresses, thereby increasing the reusability of the user rule engine 1918 and reducing the integration effort of editing existing code into a new system.

[0198] Fig.29A , Fig.29B , Fig.29C , Fig.29D , Fig.29E A perspective view, front view, left side view, right side view, and top view of an illustrative DCCH are shown. As an illustrative example, the control hub 165 may, for example, have a maximum length (the farthest end of the connector to the farthest end of the connector) of 121.7 mm. For example, the maximum width (e.g., the farthest end of the connector to the farthest edge of the hub body) may be 63.5 mm. In some examples, the width of the hub body may be 50.5 mm. The thickness of the body of the control hub 165 (e.g., excluding the connector) may be, for example, 16 mm. In some embodiments, the thickness of the body of the control hub 165 may have a predetermined relationship with the diameter of the connector. For example, the hub thickness may be less than or equal to the connector diameter. In some embodiments, for example, the hub thickness may be less than or equal to a predetermined multiple of the connector diameter (e.g., 1.1, 1.2, 1.5, 2).

[0199] In some embodiments, for example, the spacing between the coupling members (depicted as mounting holes) can be 40 mm. For example, the diameter of the mounting holes can be 4.5 mm. The connectors can be, for example, M12 x 1-6g / H. The connectors on the long edges can be spaced apart, for example, substantially evenly spaced (e.g., 20 mm apart). The connectors as a group can be, for example, centered on the edge. A single connector on a short edge can be, for example, 32.3 mm from a plane protruding from the body and coupled to a connector on a vertical plane. For example, two connectors on a short edge can be positioned 12.3 mm from a plane on the nearest vertical edge. A second connector can be, for example, positioned 32.3 mm from the same plane. The position of the connector can be, for example, in the center.

[0200] These illustrative dimensions may be scalable, for example (e.g., based on the ratio and / or distribution of components). Other embodiments may be configured with other dimensions and / or dimensional ratios. In various embodiments, the control hub 165, the communication hub 155, and / or the dual port communication hub 156 may advantageously provide a compact housing. For example, compared to a conventional "block" type form factor (e.g., in Figure 16A-16B The compact form factor can advantageously save space and / or weight compared to the conventional form factor shown in FIG.

[0201] In various embodiments, the communication hub 155, the dual-port communication hub 156, and / or the control hub 165 may include an overmolded structure. For example, the hub body (e.g., Figure 15A-15B and Figure 16C-Figure 17 The hub body may be substantially entirely formed by overmolding. For example, the hub body may be a unitary structure. The hub body may, for example, be continuously formed from at least one material.

[0202] In some embodiments, the hub body can be defined, for example, at least in part, by overmolding a material around one or more circuits and / or related structures. For example, a polymeric material can be molded directly around a circuit to form the body. In some embodiments, the polymeric material can be at least partially translucent. For example, in some embodiments, a first polymeric material can be molded directly around a circuit. The first polymeric material can have a first optical transparency. A second polymeric material can be molded around at least some of the first polymeric material. The second polymeric material can have a second optical transparency. The first optical transparency can be greater than the second optical transparency. In some embodiments, the thickness of the first polymeric material can be greater than the thickness of the second polymeric material. For example, the second polymeric material can be a relatively thin coating covering the first polymeric material. The second polymeric material can optically obscure the contents of the body from being seen unless the indicator is active. In some embodiments, by way of example and not limitation, the second polymeric material can be substantially 2 mm or less.

[0203] In various embodiments, for example, an overmolded design can be incorporated into an electrical connector (e.g., and associated connections). In various examples, an overmolded design can provide a hub (e.g., a communication hub 155 and / or a control hub 165, IP65, IP67, and / or IP68 rating).

[0204] Fig.29F A perspective view of an exemplary DCCH coupled to a mounting bracket is depicted. Figure 29G Depicted Fig.29F A mounting bracket configured to couple the DCCH to the rail. Fig.29H Depicted Fig.29F2900. The hub 165 is coupled to the bracket 2900. In the depicted example, the bracket 2900 is configured as an edge mount bracket (e.g., the hub 165 is mounted as if coupled along an edge of the hub 165). The hub 165 is coupled to the bracket 2900 by a coupler 2905 that operates through a coupling member (e.g., a through hole) of the hub 165.

[0205] The bracket 2900 is provided with a coupling member 2910 (e.g., an aperture as shown). Figure 29G , the rail mounting member 2920 is connected to the bracket 2900 via a coupling member 2915 (e.g., a screw as shown). In the example shown, the rail mounting member 2920 couples (e.g., releasably) the bracket 2900 to a mounting rail 2925 (e.g., a DIN rail). Thus, the hub 165 can be releasably coupled to the mounting rail 2925.

[0206] exist Fig.29H , the magnetic coupler 2930 is coupled to the bracket 2900 via a coupling member 2935 (e.g., a bolt and nut as shown). The magnetic coupler 2930 can, for example, include a permanent magnet. For example, the permanent magnet can be in a housing (e.g., steel, plastic). In some embodiments, the magnetic coupler 2930 can, for example, include an electromagnet. In some embodiments, the magnetic coupler 2930 can, for example, be selectively operable (e.g., a movable magnet that controls the magnetic field strength at the mounting surface, electromagnetism).

[0207] In some embodiments, the coupler can be provided, for example, using other mounting techniques. For example, bracket 2900 can be provided with hook and / or loop fabric. In some embodiments, bracket 2900 can be provided with hooks, for example. In some embodiments, bracket 2900 can be provided with snaps, for example. In some embodiments, bracket 2900 can be provided with an adhesive (e.g., glue, dry adhesive such as bristles). In some embodiments, bracket 2900 can be configured as a support frame (e.g., with support feet). By way of example and not limitation, in some embodiments, brackets other than bracket 2900 (e.g., 3015, 3300) can be configured to utilize at least reference Figure 29F-29H One or more mounting techniques are disclosed to couple a communication hub and / or other communication devices (eg, transducers, actuators, indicators, input devices, sensors) to a surface and / or device.

[0208] Fig.30 Depicted are exemplary stackable DCCHs in an illustrative stacking use case scenario. Fig.31A , Fig.31B , Fig.32A , Fig.32B , Fig.32C and Fig.32D Describes Fig.30 An exemplary DCCH stacking bracket is shown. Fig.33A , Fig.33B , Fig.33C and Fig.33D An exemplary DCCH stack support is depicted. Fig.34 and Fig.35 Depicted are exemplary stackable DCCHs in an illustrative offset stacking use case scenario.

[0209] like Fig.30 As shown, in the stacking scenario 3000, the hub 3005 (e.g., configured such as disclosed at least with reference to the communication hub 155) is provided with a display 3010 (e.g., a visual display, a digital display, a liquid crystal display (LCD), an LED status indicator). The hub 3005 is provided with (two) apertures 3020 on a top surface 3025. For example, the apertures 3020 can advantageously provide mounting points for the hub 3005. The first hub 3005 and the second hub 3005 are mounted to each other by brackets 3015 on a plane parallel to a plane defined by the longitudinal axis and the transverse axis of the hub 3005. Various ports are provided on an edge surface 3030 of the hub 3005. In various embodiments, the top surface 3025 can extend on a plane that intersects the edge surface 3030. For example, the edge surface 3030 can be located at the periphery of the hub 3005. In some embodiments, the top surface 3025 can include at least one visual mark configured to indicate a connection status of a connection port.For example, the connectors can be evenly distributed on the edge surface (edge ​​surface 3030).

[0210] like Fig.31B As shown, the bracket 3015 includes a coupling element (hole 3105) in a first mounting plate and a coupling element (hole 3110) in a second mounting plate. For example, the first and second mounting plates can extend in the same direction in respective parallel planes. In this example, the bracket 3015 offsets the unit in at least two directions. It vertically lifts the second unit (e.g., a distance D2 determined by the vertical distance between the first plate and the second plate) while also horizontally offsetting the second unit (e.g., offsetting the distance D1 along the transverse axis). The bracket 3015 can be oriented, for example, in either direction to offset the hub 3005 distally (toward the arrow) and / or proximally (away from the arrow) along the transverse axis.

[0211] In some embodiments, when the first mounting plate releasably couples the hub 3005 and the second mounting plate releasably couples to a second hub similar to the hub 3005, the hubs are fixedly held in substantially parallel respective horizontal planes. For example, the hub 3005 can be offset from the second hub in at least two directions. For example, in a first direction, the respective horizontal planes are offset by D2 along a vertical axis. For example, in a second direction, the hub 3005 and the second hub are offset by D1. For example, the connection status of the plurality of connection ports on the edge surface 3030 can be visible in at least one viewing angle along the vertical axis.

[0212] In various embodiments, the configuration of the hub 3005 and / or the bracket 3015 can, for example, advantageously implement a method of stacking multi-port input / output (I / O) blocks in a small footprint while still allowing a user to monitor the visual status of each port. As an example and not limitation, the I / O blocks can be configured for various communication protocols. The communication protocol can, for example, include IO-Link. The communication protocol can, for example, include Ethernet, EtherCat, or some combination thereof. The communication protocol can, for example, include one or more Modbus protocols. The communication protocol can, for example, include discrete I / O.

[0213] The visual state can be visually indicated, for example, by an LED (not shown) that displays the port state. The visual state can be indicated, for example, by a display 3010. By way of example and not limitation, the state can correspond to the power, output, and / or health of the device connected to the port. By way of example and not limitation, the connected device can include various sensors, such as photoelectric sensors and / or electronic sensors. The connected device can, for example, include an actuator (e.g., a motor actuator, a pneumatic valve). By way of example and not limitation, the visual state can indicate that the connected device has electricity. The visual state can, for example, indicate whether the sensor output is activated. For example, the visual state can indicate the health of the device. For example, the hub 3005 can determine whether the device is actually connected to the port and generate a corresponding visual state indication. The visual state signal can, for example, advantageously enable monitoring and / or troubleshooting of an automation system and / or network.

[0214] For example, offset mounting can advantageously make physical connection of ports easier. For example, offset mounting of stacked hubs can maximize the spacing between connection points.

[0215] As shown, the bracket 3015 includes two through holes 3110 (e.g., configured to receive threaded fasteners for mounting to the first hub 3005). The bracket 3015 includes four (threaded) holes 3105. The holes 3105 can, for example, be configured as drilled / tapped holes in the material of the bracket 3015. As shown, the holes 3105 can be configured as press-fit threaded inserts. For example, these threaded inserts can advantageously make assembly easier by providing a lead-in for the fasteners. The threaded inserts can have an increased length to provide more threads. For example, for stability, the size of the threaded inserts can match the height offset. Multiple holes 3105 can, for example, allow the upper hub 3005 to be offset in a third direction along the longitudinal axis by a distance D3 (e.g., coupling the hub 3005 to the hub 3005 via a left pair of holes 3105 or in a right pair of holes 3105).

[0216] Fig.31A The bracket 3015 depicted in FIG. 3014 may be, for example, configured in accordance with at least reference Fig.31B The disclosed manner may be configured and / or used with different inserts assembled to the hole 3015. For example, the insert may be press fit. For example, the insert may be threaded. The insert may, for example, have a smooth inner bore (e.g., configured as a cylindrical spacer). For example, the insert may not include Fig.31B In some embodiments, Fig.31A and / or Fig.31B The bracket 3015 shown can be configured to have a support lip, such as Figures 32A-33D shown.

[0217] like Figure 33A-Figure 33D As shown, the second bracket 3300 can be configured, for example, as at least Fig.30 As disclosed herein. As shown, the second bracket 3300 does not include a threaded insert. In some embodiments, fasteners (e.g., nuts and bolts, rivets, fir tree fasteners) can couple the hubs to the second bracket 3300. The second bracket 3300 can offset two stacked hubs, for example, in a vertical axis, a longitudinal axis, and / or a transverse axis.

[0218] As an illustrative example, the diameter of the two lower through holes shown (e.g., for mounting a first hub) can be 5 mm. The lower holes can be, for example, 40 mm apart (e.g., on center). The corresponding tabs can be, for example, 12 mm wide. For example, the tabs can protrude outward by 10.07 mm. The diameter of the four upper through holes shown can be, for example, 7.14 mm. For example, the upper holes can be evenly distributed. For example, the upper holes can be spaced 20 mm apart (e.g., on center). For example, one or two outer holes of the upper holes can be spaced 7 mm from the edge of the bracket. A row of lower holes can be, for example, spaced 18.5 mm apart (e.g., on center) from a row of upper holes. The upper and lower holes can be offset from each other (e.g., as shown in FIG. 2 ). Fig.33B Half the spacing of the upper holes (eg, 10 mm) as shown. For example, the bracket may be 8.6 mm high.

[0219] These illustrative dimensions may be scalable, for example (eg, based on the ratio and / or distribution of components). Other embodiments may be configured with other dimensions and / or dimensional ratios.

[0220] like Fig.34 As shown, illustrative scene 3400 depicts upper hub 3405 and lower hub 3410 stacked together with power applied. For example, upper hub 3405 and / or lower hub 3410 can be control hub 165. For example, upper hub 3405 and / or lower hub 3410 can be communication hub 155. In the described example, upper hub 3405 and lower hub 3410 are offset vertically, laterally (distance D5) and longitudinally (distance D4). As shown, when looking straight and at various angles, LEDs 3420 from all 8 ports 3415 can be seen. In some embodiments, D4 can be configured according to the distance between adjacent connection ports of hub 3005. For example, D4 ​​can be half the distance between adjacent connection ports of hub 3005.

[0221] Fig.35 An illustrative scenario 3500 is shown. In scenario 3500, upper hub 3405 and lower hub 3410 are stacked and accessories are connected together. As shown, inline connector 3505 (e.g., configured as disclosed at least with reference to inline converter 145 with status indicator 630) is coupled to two of ports 3415. In the depicted example, in addition to LED 3420, inline connector 3505 is also visible due to the offset. In some embodiments, the three cable groups on the left can be configured, for example, as lighting cable groups, and they will also be advantageously easy to view.

[0222] Fig.36 , Fig.37A and Fig.37BAn exemplary stackable communication hub (e.g., communication hub 155) in an illustrative alternating offset stacking use case scenario is depicted. Exemplary scenario 3600 (and corresponding side view 3700) depicts three units (upper unit 3005A, middle unit 3005B, and lower unit 3005C) stacked alternately to the right and then to the left. For example, additional units can be stacked and alternated as needed (e.g., to save space). The three units are stacked together in an alternating manner. As shown, the offset distance in all three directions can be, for example, substantially 1 / 2 of the connector-to-connector spacing (D6). Such an embodiment can, for example, advantageously maximize spacing (e.g., advantageously aiding in the physical connection of cables). In various embodiments, due to D6 and the offset introduced by bracket 3015, ports 3415 and ports 3610 of the three units 3005A-C can advantageously be clearly visible.

[0223] Fig.37B Another side view 3701 is shown with a bracket 3016. The bracket 3016 can, for example, have a left-handed version and a right-handed version, as shown. The handedness can be selected (e.g., alternating as shown) to create a desired offset direction.

[0224] Fig.38 , Fig.39 , Fig.40 , Fig.41 and Fig.42 Depicted are exemplary distributed communications and control systems in illustrative use case scenarios.

[0225] like Fig.38 As shown, system 3800 includes a robotic arm 3805 in a work cell 3810. Communication hub 155 is coupled to a plurality of IO-Link edge devices 3815 (e.g., IO-Link sensors, non-IO-Link sensors, IO-Link buttons). Communication hub 155 is also coupled to non-IO-Link sensors 3820 (e.g., analog sensors) via in-line converters 145 (e.g., analog ←→ IO-Link).

[0226] like Fig.39As shown, system 3900 includes a plurality of edge devices 105 coupled to a control hub 165. Some non-IO-Link edge devices 105 are coupled to the control hub 165 via corresponding in-line converters 145. The (IO-Link) edge devices 105 are coupled to a communication hub 155. The communication hub 155 is coupled to the control hub 165. The control hub 165 is coupled to a wireless communication device 160. For example, the control hub 165 can be connected to a remote communication gateway 170 via the wireless communication device 160. For example, the control hub 165 can be connected to a cloud network 175 via the wireless communication device 160. For example, the control hub 165 can be connected to one or more visualization devices 180 via the wireless communication device 160.

[0227] System 3900 may, for example, correspond to a state monitoring application. System 3900 may, for example, advantageously mix wired and wireless architectures. Various components (e.g., control hub 165, communication hub 155, online converter 145) may advantageously enable (substantially) monitoring of any device (e.g., using online converter 145). For example, system 3900 may advantageously be easily scalable. Signals and / or result data may, for example, be shared with a local control system. Data may, for example, be pushed (e.g., by control hub 165 and wireless communication device 160) to a dashboard to advantageously visualize data.

[0228] System 3900 may correspond to a condition monitoring application, for example. Signals and / or result data may be shared, for example, with a local control system. Data may be pushed (e.g., by control hub 165 and wireless communication device 160) to a dashboard, for example, to advantageously visualize the data.

[0229] like Fig.40 As shown, the system 4000 can be configured with edge devices, converters, connector hubs, communication hubs, and control hubs 165, such as Fig.39 In the example depicted in system 4000, control hub 165 is connected to a remote communication gateway 170. Remote communication gateway 170 may, for example, communicate with a remote (eg, cloud) data transmission, processing, viewing, and / or storage system.

[0230] like Fig.41As shown, the system 4100 includes an edge device 105 coupled to a dual-port communication hub 156. The dual-port communication hub 156 is coupled to a control hub 165. The edge device 105 is coupled to the communication hub 155. The multi-drop connector 135 is coupled to the second communication hub 155. Both communication hubs 155 are coupled to the control hub 165. The control hub 165 can be coupled to an IPC robot controller, for example. The system 4100 can correspond to an IO-Link to Ethernet / IP configuration, for example. In the illustrative example, the control hub 165, depicted as a DXM R90x in this example, can be configured to operate as a Modbus master controller, which in some embodiments can share some similarities with an IO-Link master.

[0231] like Fig.42 As shown, system 4200 includes multiple edge devices 105 coupled to a control hub 165 (e.g., some through corresponding online converters 145, some directly, and some through multi-branch connectors 135, as shown). System 4200 can, for example, correspond to an intelligent controller application. System 4200 can, for example, implement various components (e.g., online converters 145, control hub 165) as an alternative to wireless status monitoring. Various components (e.g., online converters 145, control hub 165) can advantageously aggregate sensor information from multiple locations.

[0232] The control hub 165 may, for example, provide scripts and / or programming (eg, via profiles 1918a stored on the memory module 1915 and executed by the processor 1820 according to the corresponding engine 1918).

[0233] For example, the control hub 165 may advantageously allow the use of Industrial Ethernet and / or MQTT to get data to where the user needs it.

[0234] Fig.43 An exemplary distributed communication and control architecture 4300 with remote communications is depicted. In this example, in a facility (e.g., a manufacturing facility), various edge devices (e.g., edge devices 105) in a collection layer 4305 can be configured to provide data (e.g., measurement data, process data, environmental data) to a transport layer 4310. The transport layer 4310 transmits the collected data to an aggregation and distribution layer 4315 (e.g., via a remote communication gateway 170). For example, the aggregation and distribution layer 4315 can include various cloud services (e.g., in a cloud network 175). At the consumption layer 4320, various users (e.g., analysts, managers, workers) can access the aggregated data to perform, for example, analysis and decision making for the facility.

[0235] Fig.44 An exemplary telecommunication gateway is depicted. In some embodiments, the telecommunication gateway 170 can advantageously provide flexibility for data integration. The telecommunication gateway 170 can, for example, be equipped with a Linux operating system (OS). For example, the OS can advantageously be easily configured for client-specific data infrastructure. For example, the OS of the telecommunication gateway 170 can advantageously accept configurations for various cloud infrastructures (e.g., third-party cloud systems). The telecommunication gateway 170 can, for example, be customized to interact with a customized application programming interface (API).

[0236] Various embodiments may advantageously allow users to write their own computations using popular modern programming languages ​​in custom containers.

[0237] In various embodiments, telecommunications gateway 170 may advantageously provide flexibility and customization beyond built-in platforms or proprietary components.

[0238] For example, in some embodiments, the Linux OS can be configured to run one or more third-party software packages. Such software packages can, for example, implement an Internet of Things (IoT) core and / or analysis tools directly on the telecommunications gateway 170. Such embodiments can advantageously reduce communication costs (e.g., via a cellular network). Such embodiments can, for example, advantageously reduce processing costs in the cloud (e.g., by performing at least some processing directly on the telecommunications gateway 170).

[0239] Fig.45 An exemplary remote communication hub in an illustrative use case scenario of an exemplary distributed communication and control system 4500 is depicted. As shown, the system 4500 includes a control hub 165 and a compatible edge device 4505. The remote communication gateway 170 receives data from the control hub 165 and the compatible edge device 4505 and transmits the data to various cloud services. For example, the cloud service may include Amazon Web Services provided by Amazon Web Services, Inc. located in Seattle, Washington. For example, the cloud service may include Microsoft Azure IoT Hub provided by Microsoft Corporation located in Redmond, Washington. For example, the cloud service may include OSISoft PI System provided by OSISoft LLC located in San Leandro, California. For example, the cloud service may include Ignition provided by Inductive Automation located in Folsom, California.

[0240] Fig.46An exemplary configurable multi-output safety controller in an illustrative use case scenario in an exemplary distributed communication and control system is depicted. In the illustrative scenario, the system 4600 may, for example, include multiple edge devices 4610. The safety controller 4605 may be connected to the multiple edge devices 4610, for example, using an online converter 145. For example, the safety controller 4605 may be advantageously configured to provide serial diagnostics. For example, the safety controller 4605 may be configured to connect to up to 68 inputs 4615. The safety controller 4605 is configured with two independent serial diagnostic outputs 4620. For example, two independent serial diagnostic outputs 4620 (e.g., chain outputs) can independently shut down hazardous floor areas based on inputs 4615. For example, each chain can be associated with 32 inputs in any combination. In the described example, 6 terminals 4635 are still available for up to 4 other devices. As shown, the safety controller 4605 can communicate with a USB device via port 4625. The safety controller 4605 can communicate with a network (e.g., Ethernet / IP, ProfiNet, Modbus TCP / IP) via the RJ45 port 4630.

[0241] Although various embodiments have been described with reference to the figures, other embodiments are possible.

[0242] Although example systems have been described with reference to the accompanying figures, other implementations may be deployed in other industrial, scientific, medical, commercial, and / or residential applications.

[0243] In various embodiments, Modbus can advantageously provide a robust communication network. For example, Modbus (using differential signaling) can support a communication distance of up to 1200 meters. For example, system communication via Modbus can advantageously provide reliable communication over long distances.

[0244] Reference is made to one or more illustrative existing signal types and / or communication standards (e.g., Modbus, IO-Link, Ethernet, Various embodiments are depicted and / or described using the concepts of (SCADA, discrete, analog). It will be appreciated by those of ordinary skill in the art that these communication standards are exemplary embodiments, and that other signal types and / or communication standards are within the scope of the embodiments disclosed herein. For example, converters and / or other communication devices may have more, fewer, and / or different signal and / or communication standard options than shown in a given illustration. In some embodiments, for example, converters and / or other communication devices may be dynamically configured (e.g., via hardware, programming, remote) to add, remove, and / or change available signal and / or communication standard options.

[0245] Various embodiments can, for example, advantageously reduce wiring. For example, local hubs and / or controllers (e.g., communication hub 155, dual-port communication hub 156, control hub 165) can reduce the number of cables that need to be provided to an upstream controller. Various embodiments can advantageously reduce the risk of breakage from multiple cables. Various embodiments can, for example, advantageously reduce the weight of cables, such as cables on a building, machine, support structure, or some combination thereof.

[0246] Various embodiments may, for example, overmold electronic devices (e.g., one or more circuits). Such embodiments may, for example, completely encapsulate electronic components. Overmolds may, for example, bond body (housing) material to electrical connectors (e.g., and associated connections). Various embodiments may, for example, advantageously provide elongated overmold designs.

[0247] Overmolding may, for example, advantageously reduce the size of the housing.Overmolding may, for example, advantageously reduce assembly costs.

[0248] In some embodiments (e.g., overmolded embodiments), the device (e.g., inline converter 145, communication hub 155, dual-port communication hub 156, control hub 165) can be configured to withstand external pressure and / or moisture. For example, some such devices can be configured to withstand washdown. For example, the body can be configured to withstand water ingress even when fully submerged. For example, the body can withstand water ingress when submerged in 1 meter of water for up to 30 minutes. Thus, for example, the body can obtain an IP67 rating for use in applications requiring water submersion (e.g., washdown).

[0249] Various embodiments (e.g., overmolded) can be configured, for example, to withstand pressures up to about 1100 pounds per square inch (psi). Some embodiments can, for example, be configured to resist the ingress of high temperature (e.g., steam), high pressure cleaning (e.g., 80 degrees Celsius water sprayed at about 1160-1450 psi). The body can resist the ingress of water at a flow rate of up to 16 liters per minute. Thus, for example, the body can obtain an IP69K rating for applications requiring high pressure, high temperature washing to sterilize the device.

[0250] In some overmolding embodiments, the electronic component (e.g., component array) can be bottom-filled. For example, material can be deposited (e.g., injected) under the component before overmolding. Such an embodiment can, for example, advantageously prevent the component from breaking during overmolding (e.g., under pressure).

[0251] For example, in some embodiments, a body (e.g., an overmolded body) configured to resist water and / or dust ingress can advantageously simplify installation in various locations. For example, such embodiments can advantageously reduce or eliminate the need for a protective enclosure (e.g., a control cabinet).

[0252] In some embodiments, overmolding can be performed in a multi-shot process. For example, a first shot can at least partially encapsulate the circuit in a first polymeric material. A second shot can at least partially encapsulate the first polymeric material, for example, with a second polymeric material.

[0253] In some embodiments, the first polymeric material can be optically transparent. In some embodiments, the second polymeric material can be partially translucent. The second polymeric material can be, for example, black. In some embodiments, the second polymeric material can be, for example, substantially optically transparent. In some embodiments, various color and / or optical translucency combinations can be used (e.g., to achieve desired aesthetic and / or indicator visibility effects).

[0254] In various embodiments, some bypass circuit implementations may be controlled in response to signals from analog or digital components, which may be discrete, integrated, or a combination of each thereof. Some embodiments may include a programmed device, a programmable device, or some combination thereof (e.g., a PLA, a PLD, an ASIC, a microcontroller, a microprocessor), and may include one or more data storage devices (e.g., cells, registers, blocks, pages) that provide single-level or multi-level digital data storage capabilities and may be volatile, non-volatile, or some combination thereof. Some control functions may be implemented in hardware, software, firmware, or any combination thereof.

[0255] A computer program product may include a set of instructions that, when executed by a processor device, causes the processor to perform specified functions. These functions may be performed in conjunction with a controlled device in operable communication with the processor. A computer program product, which may include software, may be stored in a data storage device tangibly embedded on a storage medium, such as an electronic, magnetic, or rotating storage device, and may be fixed or removable (e.g., hard disk, floppy disk, thumb drive, CD, DVD).

[0256] Although examples of systems that may be portable have been described with reference to the above figures, other implementations may be deployed in other processing applications, such as desktop and networked environments.

[0257] For example, temporary auxiliary energy input can be received from a rechargeable or disposable battery, which can enable use in portable or remote applications. Some embodiments can operate using other DC voltage sources, such as a 9V (nominal) battery. An alternating current (AC) input, such as provided from a 50 / 60Hz power port or from a portable generator, can be received via a rectifier and appropriate scaling. The supply of an AC (e.g., sine wave, square wave, triangle wave) input can include a line frequency converter to provide voltage step-up, voltage step-down, and / or isolation.

[0258] Although specific features of the architecture have been described, other features may be combined to improve performance. For example, cache (e.g., L1, L2, ...) techniques may be used. Random access memory may be included, for example, to provide a scratch pad memory and / or load executable code or parameter information stored for use during runtime operations. Other hardware and software may be provided to perform operations, such as network or other communications using one or more protocols, wireless (e.g., infrared) communications, stored operating energy and power (e.g., batteries), switching and / or linear power supply circuits, software maintenance (e.g., self-testing, upgrading), etc. One or more communication interfaces may be provided to support data storage and related operations.

[0259] Some systems may be implemented as computer systems that can be used with various implementations. For example, various implementations may include digital circuits, analog circuits, computer hardware, firmware, software, or a combination thereof. The apparatus may be implemented in a computer program product that is tangibly embodied in an information carrier, such as a machine-readable storage device, for execution by a programmable processor; and the method may be performed by a programmable processor executing an instruction program to perform the functions of the various embodiments by operating on input data and generating output. Various embodiments may advantageously be implemented in one or more computer programs that are executable on a programmable system that includes at least one programmable processor coupled to receive data and instructions from and transmit data and instructions to a data storage system, at least one input device, and / or at least one output device. A computer program is a set of instructions that can be used directly or indirectly in a computer to perform a specific activity or produce a specific result. Computer programs may be written in any form of programming language, including compiled or interpreted languages, and may be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.

[0260] As examples, suitable processors for executing instruction programs include general and special purpose microprocessors, which may include a single processor or one of multiple processors of any type of computer. Typically, the processor will receive instructions and data from a read-only memory or a random access memory or both. The key elements of a computer are a processor for executing instructions and one or more memories for storing instructions and data. Typically, a computer will also include one or more mass storage devices for storing data files, or be operatively coupled to the one or more mass storage devices to communicate with them; such devices include disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including, as examples, semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and memory may be supplemented by or incorporated into an ASIC (Application Specific Integrated Circuit).

[0261] In some implementations, each system can be programmed with the same or similar information and / or initialized with substantially the same information stored in volatile and / or non-volatile memory. For example, one data interface can be configured to perform auto-configuration, auto-download, and / or auto-update functions when coupled to an appropriate host device (such as a desktop computer or server).

[0262] In some implementations, one or more user interface features may be custom configured to perform a specific function. Various embodiments may be implemented in a computer system that includes a graphical user interface and / or an Internet browser. To provide interaction with a user, some implementations may be implemented on a computer having a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user, a keyboard, and a pointing device (e.g., a mouse or trackball) through which the user can provide input to the computer.

[0263] In various implementations, the system may communicate using suitable communication methods, equipment, and techniques. For example, the system may communicate with compatible devices (e.g., devices capable of transmitting data to and / or from the system) using point-to-point communication, in which messages are transmitted directly from a source to a receiver via a dedicated physical link (e.g., a fiber optic link, point-to-point wiring, a daisy chain). The components of the system may exchange information via analog or digital data communication of any form or medium, including packet-based messages on a communication network. Examples of communication networks include, for example, a LAN (local area network), a WAN (wide area network), a MAN (metropolitan area network), wireless and / or optical networks, computers and networks forming the Internet, or some combination thereof. Other implementations may transmit messages by broadcasting to all or substantially all devices coupled together by a communication network, such as by using omnidirectional radio frequency (RF) signals. Still other implementations may transmit messages characterized by high directivity, such as RF signals transmitted using directional (i.e., narrow beam) antennas or infrared signals that may optionally be used with focusing optics. Other implementations are possible using appropriate interfaces and protocols, such as, by way of example but not limitation, USB 2.0, Firewire, ATA / IDE, RS-232, RS-422, RS-485, 802.11a / b / g, Wi-Fi, Ethernet, IrDA, FDDI (Fiber Distributed Data Interface), Token Ring, multiplexing techniques based on frequency division, time division or code division, or some combination thereof. Some implementations may optionally incorporate features such as error checking and correction (ECC) for data integrity, or security measures such as encryption (e.g., WEP) and password protection.

[0264] In various embodiments, a computer system may include an Internet of Things (IoT) device. An IoT device may include an object embedded with electronics, software, sensors, actuators, and network connectivity that enables these objects to collect and exchange data. An IoT device may send data to another device through an interface, thereby being used with wired or wireless devices. An IoT device may collect useful data and then autonomously transfer (flow) the data between other devices.

[0265] Various examples of modules can be implemented using circuits including various electronic hardware. As an example and not limitation, the hardware can include transistors, resistors, capacitors, switches, integrated circuits, other modules, or some combination thereof. In various examples, the modules can include analog logic, digital logic, discrete components, traces, and / or memory circuits manufactured on a silicon substrate, including various integrated circuits (e.g., FPGAs, ASICs), or some combination thereof. In some embodiments, the modules can involve the execution of pre-programmed instructions, software executed by a processor, or some combination thereof. For example, various modules may involve both hardware and software.

[0266] In illustrative aspects, the offset bracket (e.g., 3015) may include a first set of coupling elements (e.g., 3105) distributed along a first mounting plate on a longitudinal axis. The offset bracket may include a second set of coupling elements (e.g., 3110) distributed along a second mounting plate in a direction parallel to the longitudinal axis. The second mounting plate may be located at a predetermined lateral offset distance from the first mounting plate along a lateral axis orthogonal to the longitudinal axis. The first set of coupling elements and the second set of coupling elements may be configured such that when the first mounting plate is releasably coupled to the first communication hub and the second mounting plate is releasably coupled to the second communication hub, the first communication hub and the second communication hub are fixedly maintained on substantially parallel corresponding horizontal planes, and the first communication hub is offset from the second communication hub in at least two directions. In the first direction, the corresponding horizontal planes may be offset along the vertical axis by a predetermined first offset distance. In the second direction, the first communication hub and the second communication hub may be offset by a predetermined second offset distance. The first direction may be orthogonal to the second direction, such that the connection status of a plurality of connection ports on edge surfaces of the first communication hub and the second communication hub is visible in at least one viewing angle along the vertical axis.

[0267] The offset bracket may include a first communication configured such that when the second offset bracket releasably couples the third communication hub to the first communication hub, the first communication hub and the third communication hub are offset in a third direction. In the third direction, the first communication hub and the third communication hub may be offset by a predetermined second offset distance.

[0268] Each of the first set of coupling elements may include a threaded insert to provide a lead-in passage for a fastener.

[0269] The second set of coupling elements may include vias.

[0270] At least one of the first set of coupling elements and the second set of coupling elements may include a press-in insert.

[0271] The offset bracket may include a first communication hub. The first communication hub may include a top surface extending in a plane intersecting the edge surface. The top surface may include at least one visual marker configured to indicate a connection status of the plurality of connection ports. The at least one visual marker may include an LED status indicator. The at least one visual marker may include a liquid crystal display.

[0272] The offset bracket may include a first communication hub and a second communication hub.The plurality of connection ports may include a configurable Modbus port.

[0273] The offset bracket may include a first communication hub and a second communication hub. A plurality of connection ports may be evenly distributed on the edge surface. A distance between adjacent connection ports may be twice the predetermined second offset distance.

[0274] In illustrative aspects, a stackable communication hub (e.g., 155, 156, 165) may include a first communication hub (e.g., 155, 156, 165) extending in a first direction on a horizontal plane. The hub may include at least one peripheral surface (e.g., 3030), which may include a plurality of connection ports (e.g., 3415) on at least one peripheral surface. The at least one peripheral surface may extend in a direction intersecting the horizontal plane. The hub may include at least one surface (e.g., 3025) having at least one coupling element (e.g., 3020) configured to be releasably coupled to an offset bracket (e.g., 3015). When the offset bracket couples the first communication hub and the second communication hub together, the first communication hub and the second communication hub may be fixedly maintained on substantially parallel respective horizontal planes. The first communication hub may be offset from the second communication hub in at least two directions. In the first direction, the respective horizontal planes may be offset by a predetermined first offset distance along a vertical axis. In the second direction, the first communication hub and the second communication hub may be offset by a predetermined second offset distance. The first direction may be orthogonal to the second direction such that connection states of the plurality of connection ports may be visible in at least one viewing angle along a vertical axis.

[0275] The at least one surface may include a top surface extending on a plane intersecting the at least one peripheral surface. The top surface may include at least one visual marker configured to indicate a connection status of the plurality of connection ports. The at least one visual marker may include an LED status indicator. The at least one visual marker may include a liquid crystal display.

[0276] The plurality of connection ports may include a configurable communication port. The configurable communication port may be selectively configured as at least one of a master port, a slave port, and a pass-through port.

[0277] The plurality of connection ports may be evenly distributed. The distance between adjacent connection ports may be twice the predetermined second offset distance.

[0278] When the second offset bracket releasably couples the third communication hub to the first communication hub, the first communication hub and the third communication hub can be offset in the third direction. In the third direction, the first communication hub and the third communication hub can be offset by a predetermined second offset distance.

[0279] The stackable communication hub may include an offset bracket. The offset bracket may include a first mounting plate extending along a longitudinal axis. The first mounting member may include a first set of coupling elements. The offset bracket may include a second mounting plate extending parallel to the longitudinal axis. The second mounting plate may include a second set of coupling elements. The first communication hub and the second communication hub may be offset by a third predetermined offset distance in a fourth direction orthogonal to the first direction and the second direction. The first set of connecting elements of the offset bracket may include threaded inserts to provide an introduction channel for a fastener. The second set of coupling elements of the offset bracket may include through holes. The first set of coupling elements of the offset bracket may include press-fit inserts.

[0280] A dynamically reconfigurable communication hub may include a plurality of independently reconfigurable connection ports (IRCPs) (e.g., 1920, 1925, 1930, 1935). The hub may include a data storage (e.g., 1915). The data storage may include an instruction program (e.g., 1918) configured to reconfigure the plurality of IRCPs. The data storage may include a plurality of configuration profiles (e.g., 1917). Each configuration profile may be associated with a corresponding IRCP in the plurality of IRCPs. The hub may include a processor (e.g., 1910) operably coupled to the data storage, such that when the processor executes the instruction program, the processor is configured to perform an automatic reconfiguration operation to independently configure the plurality of IRCPs. The operation may include receiving a reconfiguration signal from a connected device at at least one of the plurality of IRCPs. The operation may include determining a selected IRCP to be reconfigured. The operation may include retrieving from the data storage a first predetermined set of rules for identifying a communication profile of the selected IRCP based on the reconfiguration signal (e.g., 1835). The communication profile may include an operating mode and a communication protocol (e.g., 1825). The operation may include identifying a communication profile for the selected IRCP based on the first predetermined rule set. The operation may include associating the identified communication profile with the selected IRCP based on a second predetermined rule set (e.g., 1840) so that, for example, user intervention may not be required when configuring the plurality of reconfigurable connection ports. The operation may include updating a configuration profile associated with the selected IRCP in the data storage.

[0281] Operation modes may include master mode, slave mode, and pass-through mode.

[0282] The connecting device may include an edge device operably coupled to the selected IRCP. The operations may include automatically associating a preconfigured virtual address with a device address of the edge device such that the edge device is referenced by the preconfigured virtual address.

[0283] The communication profile may include the Modbus TCP protocol. The communication profile may include The communication profile may include the MQTT protocol. The communication profile may include the TCP / IP protocol.

[0284] After receiving the reconfiguration signal, operations may include interrupting a script thread executing at the processor and initiating operations at the interrupted thread.

[0285] The connected device may include a master controller device.The operations may include configuring the selected IRCP as a master port.

[0286] The connected device may be connected to the edge device through an in-line converter configured to convert incompatible signals from the edge device into signals that are compatible with the dynamically reconfigurable communication hub.

[0287] In illustrative aspects, a computer-implemented method (e.g., 2600) may be performed by at least one processor to automatically and independently configure an independent reconfigurable connection port (IRCP). The method may include receiving a reconfiguration signal at the IRCP (e.g., 2605). The method may include retrieving a first predetermined rule set from a first data storage for identifying a communication profile of the IRCP based on the reconfiguration signal. The communication profile may include an operating mode and a communication protocol (e.g., 2610). The method may include identifying an operating mode of the IRCP based on the first predetermined rule set (e.g., 2615). Based on the first predetermined rule set, the operating mode may include at least one of a master port, a slave port, and a pass-through port. The method may include identifying a communication protocol with the IRCP based on a second predetermined rule set (e.g., 2620). The method may include generating a configuration profile based on the operating mode and the communication protocol (e.g., 2625). The method may include storing an association between the configuration profile and the IRCP in a second data storage.

[0288] Operation modes may include master mode, slave mode, and pass-through mode.

[0289] A reconfigurable signal may be received from an edge device operably coupled to the IRCP. The method may include automatically associating a preconfigured virtual address with a device address of the edge device such that the edge device is referenced by the preconfigured virtual address. The method may include updating a configuration profile associated with the IRCP with the association between the preconfigured virtual address and the device address.

[0290] The reconfigurable signal may be received from a master controller device.The method may include configuring the IRCP as a master port.

[0291] The communication profile may include the Modbus TCP protocol. The communication profile may include The communication profile may include the MQTT protocol. The communication profile may include the TCP / IP protocol.

[0292] In illustrative aspects, a distributed communication and control system (e.g., 100) may include at least one edge device (e.g., 105). The system may include a first dynamically reconfigurable communication hub (e.g., 155). The hub may include a plurality of independently reconfigurable connection ports (IRCPs) (e.g., 1920, 1925, 1930, 1935). The hub may be operably coupled to at least one edge device. The dynamically reconfigurable communication hub may be configured to perform an automatic reconfiguration operation to independently configure each of the plurality of IRCPs. The operation may include receiving a communication signal from one of the at least one edge device at one of the plurality of IRCPs. The operation may include determining a selected IRCP to be reconfigured. The operation may include retrieving from a first data storage a first predetermined set of rules (e.g., 1835) for identifying a communication profile (e.g., 1917) of a selected IRCP based on the received communication signal and a second set of rules (e.g., 1840) for associating the communication profile with the selected IRCP. The communication profile may include an operating mode and a communication protocol (e.g., 1825). The operation may include identifying a communication profile for the selected IRCP based on the first predetermined rule set. The operation may include associating the communication profile with the selected IRCP based on a second predetermined rule set (e.g., 1840) so that, for example, user intervention may not be required when configuring multiple IRCPs. The operation may include updating an association in a configuration profile associated with the IRCP in a data store.

[0293] The operations may include automatically associating a preconfigured virtual address to a device address of the at least one edge device such that the at least one edge device is referenced by the preconfigured virtual address.

[0294] The system may include a second dynamically reconfigurable communication hub. The first dynamically reconfigurable communication hub and the second dynamically reconfigurable communication hub may be operably coupled via a control network. The control network may include a Modbus network.

[0295] The system may include an in-line converter coupled in series to an edge device and a first dynamically reconfigurable communication hub. The at least one edge device may include an incompatible device configured to generate an incompatible signal. The in-line converter may be configured to convert the incompatible signal into a compatible signal for the first dynamically reconfigurable communication hub.

[0296] Incompatible signals may include analog signals. Incompatible signals may include discrete signals. Incompatible signals may include IO-Link signals.

[0297] The at least one edge device may include an indicator device. The at least one edge device may include an actuator. The at least one edge device may include a motor. The at least one edge device may include an IO-Link sensor. The at least one edge device may include an IO-Link input device. The at least one edge device may include a robotic device. The at least one edge device may include a sensor.

[0298] The first dynamically reconfigurable communication hub can be connected to a remote computer device via a communication network. A configuration signal can be received from the remote computer device via the communication network.

[0299] In illustrative aspects, the communication hub may include a plurality of independent reconfigurable connection ports (IRCPs) (e.g., 1920, 1925, 1930, 1935) that may be configured as at least one of a master port, a slave port, and a pass-through port. The hub may include a memory module (e.g., 1915). The memory module may include at least an interrupt instruction program (e.g., 1911) and a script instruction program (e.g., 1912). The hub may include a processor (e.g., 1910) operably coupled to the memory module and configured to execute the interrupt instruction program and the script instruction program. The hub may include a shared data register (e.g., 1916) configured to be accessible via the processor. The hub may include a data storage device that stores a plurality of configuration profiles (e.g., 1917). When the interrupt instruction program and the script instruction program are executed, one of multiple configuration profiles can be identified and applied, so that when an input signal is received from a connected device coupled to one of the multiple IRCPs, based on the applied configuration profile, the processor executes: (a) an interrupt instruction program to perform at least one of the following: storing data corresponding to the input signal in a shared data register, and configuring multiple IRCPs, and, (b) a script instruction program for identifying the shared data register associated with the input signal and generating an output signal at one or more of the multiple IRCPs based on the data stored in the shared data register.

[0300] Multiple IRCPs may be configured to be operably coupled to a Modbus network. Multiple IRCPs may be configured to be operably coupled to an IO-Link network.

[0301] The shared data registers can be configured to be globally accessible via multiple IRCPs and processors. The shared data registers can be configured to store 16-bit data. The shared data registers can be configured to store 32-bit data.

[0302] The memory module may include a plurality of protocol profiles, each protocol profile corresponding to one of the plurality of IRCPs. Each protocol profile may include rules and operations executed by the interrupt instruction program and the script instruction program for the corresponding IRCP.

[0303] The connected devices may include incompatible devices configured to generate incompatible signals. The communication hub may be serially connected to the incompatible devices via an inline converter. The inline converter may be configured to convert the incompatible signal into a compatible signal using at least one of the plurality of configuration profiles.

[0304] Incompatibilities can include analog signals. Incompatibilities can include discrete signals.

[0305] Compatible signals may include IO-Link signals.

[0306] The connected device may include an indicator device. The connected device may include an actuator. The connected device may include a motor. The connected device may include an IO-Link sensor. The connected device may include an IO-Link input device. The connected device may include a robotic device. The connected device may include a sensor.

[0307] In illustrative aspects, a computer-implemented method (e.g., 2500) may be performed by at least one processor to process communication signals at an independently reconfigurable connection port (IRCP). The method may include receiving an input signal from a connected device at one of the IRCPs (e.g., 2505). The method may include identifying a next operation (e.g., 2515) based on a configuration profile associated with the IRCP receiving the input signal. The method may include, upon determining that the next operation is a write operation (e.g., 2530), then storing data corresponding to the input signal in a shared data register (e.g., 2535). The method may include, upon determining that the next operation is a configuration operation (e.g., 2555), then reconfiguring the IRCP based on a predetermined set of rules. The method may include, upon determining that the next operation is a read operation (e.g., 2540), then identifying a shared data register associated with the input signal (e.g., 2545). The method may include generating an output signal in at least one IRCP based on the data stored in the shared data register (e.g., 2550).

[0308] Storing data corresponding to the input signal in a shared data register may include identifying a device address based on the input signal. The device address may be an identification of an edge device that sent the input signal. Storing data corresponding to the input signal in a shared data register may include determining a virtual address of the shared data register based on an IRCP corresponding to the input signal. Storing data corresponding to the input signal in a shared data register may include storing the data corresponding to the input signal in the shared data register at the virtual address.

[0309] The configuration operation may include retrieving from the first data storage a first predetermined rule set for identifying a communication profile of the IRCP based on the input signal and a second predetermined rule set for associating the communication profile with the IRCP. The communication profile may include an operating mode and a communication protocol. The configuration operation may include identifying the communication profile of the corresponding IRCP based on the first predetermined rule set. The configuration operation may include associating the identified operating mode and communication protocol with the IRCP based on the second predetermined rule set.

[0310] Input signals can be received via a Modbus network. Input signals can be received via an IO-Link network. Input signals can be received via a Network reception. Input signals can be received via Ethernet.

[0311] The connected device may include an indicating device. The connected device may include an actuator. The connected device may include a motor. The connected device may include an IO-Link sensor. The connected device may include an IO-Link input device. The connected device may include a robotic device. The connected device may include a sensor.

[0312] In illustrative aspects, a distributed communication and control system (e.g., 100) may include at least one edge device (e.g., 105). The system may include a first dynamically reconfigurable communication hub (e.g., 155). The hub may include a plurality of independent reconfigurable connection ports (IRCPs) (e.g., 1920, 1925, 1930, 1935) configured to be configurable as at least one of a master port, a slave port, and a pass-through port. The hub may include a memory module (e.g., 1915) including at least an interrupt instruction program (e.g., 1911) and a script instruction program (e.g., 1912). The hub may include a processor (e.g., 1910) operably coupled to the memory module and configured to execute the interrupt instruction program and the script instruction program. The hub may include a shared data register (e.g., 1916) configured to be accessible via the processor. The hub may include a data storage device storing multiple configuration profiles (e.g., 1917) so that when an interrupt instruction program and a script instruction program are executed, at least one of the multiple configuration profiles is identified and applied, so that when an input signal is received from one of the multiple IRCPs, based on the applied configuration profile, the processor executes: (a) an interrupt instruction program to perform at least one of the following: storing data corresponding to the input signal in a shared data register, and configuring the multiple IRCPs, and (b) a script instruction program for identifying a shared data register associated with the input signal and generating an output signal at one or more of the multiple IRCPs based on the data stored in the shared data register.

[0313] The operations may include automatically associating a preconfigured virtual address with a device address of the at least one edge device such that the at least one edge device is referenced by the preconfigured virtual address.

[0314] The system may include a second dynamically reconfigurable communication hub.The first dynamically reconfigurable communication hub and the second dynamically reconfigurable communication hub may be operably coupled via a control network.

[0315] The system may include an inline converter coupled in series to an edge device and a first dynamically reconfigurable communication hub. The at least one edge device may include an incompatible device configured to generate an incompatible signal. The inline converter may be configured to convert the incompatible signal into a compatible signal.

[0316] The incompatible signal may include an analog signal.The incompatible signal may include a discrete signal.

[0317] Compatible signals may include IO-Link signals.

[0318] The at least one edge device may include an indicating device. The at least one edge device may include an actuator. The at least one edge device may include a motor. The at least one edge device may include an IO-Link sensor. The at least one edge device may include an IO-Link input device. The at least one edge device may include a robotic device. The at least one edge device may include a sensor.

[0319] The first dynamically reconfigurable communication hub can be connected to a remote computer device via a communication network. A configuration signal can be received from the remote computer device via the communication network.

[0320] The first dynamically reconfigurable communication hub can be connected to a remote computer device via a communication network. A configuration signal can be received from the remote computer device via the communication network.

[0321] In illustrative aspects, an online signal processing device (e.g., 605) may include a housing (e.g., 635). The online signal processing device may include an input port (e.g., 625a) coupled to a first surface of the housing. The online signal processing device may include an output port (e.g., 625b) coupled to a second surface of the housing. The online signal processing device may include an electronic circuit coupled to the input port and the output port. The electronic circuit may include a data register (e.g., 615). The electronic circuit may include a processing circuit (e.g., 610) configured to generate a signal based on a predetermined conversion. The housing may be overmolded to completely encapsulate the electronic circuit in an integral body, such that the total thickness of the online signal processing device is less than a predetermined multiple of the maximum size of the input port and the output port, and the online signal processing device is dustproof.

[0322] The online signal processing device may include a lighting circuit. The lighting circuit may include at least one status indicator. The housing may include a transparent upper portion.

[0323] The in-line signal processing device may include a sensing circuit.

[0324] The predetermined conversion may be configured based on parameters set in the data register. The predetermined conversion may include conversion between IO-Link and Modbus protocol. The predetermined conversion may include conversion between pulse width modulated signal and Modbus protocol. The predetermined conversion may include conversion between analog sensor signal and Modbus protocol.

[0325] The input port may be configured to be coupled to the second inline signal processing device in a pass-through mode such that the input port directly receives a signal transmitted from the edge device coupled to the second inline signal processing device.

[0326] The predetermined multiple can be up to 1.5.

[0327] In illustrative aspects, a method for producing a compact inline converter (e.g., 650) may include providing an inline converter circuit (e.g., 655). The method may include underfilling an array of inline converter circuits (e.g., 660). The method may include molding a first polymeric material directly around the inline converter circuit to form a body. The first polymeric material may include a first optical transparency (e.g., 665). The method may include molding a second polymeric material around at least some of the first polymeric material. The second polymeric material may include a second optical transparency (e.g., 670) that is less than the first transparency. The first polymeric material may completely encapsulate the inline converter circuit such that the compact inline converter is dust-proof.

[0328] In illustrative aspects, an in-line thermistor may include an internal temperature sensing circuit (e.g., 1300). The in-line thermistor may include an analog-to-digital converter (ADC) (e.g., 1315) coupled to the internal temperature sensing circuit. The in-line thermistor may include an output port (e.g., 1425) configured to transmit a digital signal corresponding to the measured temperature in a predetermined protocol. The in-line thermistor may include an overmolded housing (e.g., 1405) surrounding the internal temperature sensing circuit and the ADC, such that the total thickness of the internal temperature sensing circuit is less than a predetermined multiple of the maximum dimension of the output port, and the in-line thermistor is dust-proof. At each measurement cycle, the internal temperature sensing circuit may be configured to dynamically self-calibrate based on an ADC count generated according to a reference voltage, an input voltage, and a ground voltage of the internal temperature sensing circuit, such that at least one calibration mode does not require an external reference voltage.

[0329] The predetermined multiple can be up to 1.5.

[0330] The predetermined protocol may include Modbus.The predetermined protocol may include IO-Link.

[0331] The in-line thermistor may include a sensor shroud threadably coupled to an overmolded housing.

[0332] Various illustrative product names and / or sources (e.g., cloud service providers) are disclosed herein. One of ordinary skill in the art will understand that these sources and / or product names are exemplary embodiments used to illustrate specific examples, and that the scope of the claims is not limited by these sources and / or product names.

[0333] Many implementations have been described. However, it should be understood that various modifications may be made. For example, advantageous results may be obtained if the steps of the disclosed technology are performed in a different order, or if the components of the disclosed system are combined in a different manner, or if these components are supplemented with other components. Therefore, other implementations are contemplated.

Claims

1. A dynamically reconfigurable communication hub, comprising: Multiple Independent Reconfigurable Connection Ports (IRCPs) (1920, 1925, 1930, 1935); Data storage device (1915), including: an instruction program (1918) configured to reconfigure the plurality of IRCPs; and, a plurality of configuration profiles (1917), each configuration profile being associated with a corresponding IRCP in the plurality of IRCPs; and, a processor (1910) operatively coupled to the data storage such that when the processor executes the program of instructions, the processor is configured to perform automatic reconfiguration operations to independently configure the plurality of IRCPs, the operations comprising: receiving, at at least one of the plurality of IRCPs, a reconfiguration signal from a connected device; determining the selected IRCP to be reconfigured; retrieving from the data storage a first predetermined rule set (1835) for identifying a communication profile of the selected IRCP based on the reconfiguration signal, wherein the communication profile comprises an operating mode and a communication protocol (1825), wherein the operating mode comprises a master mode, a slave mode, and a pass-through mode; identifying a communication profile of the selected IRCP based on the first predetermined rule set; associating the identified communication profile with the selected IRCP based on a second predetermined rule set (1840), the second predetermined rule set being configured to independently associate the identified communication profile with one of the plurality of IRCPs such that no user intervention is required in configuring the plurality of IRCPs; and, A configuration profile associated with the selected IRCP is updated in the data store.

2. The dynamically reconfigurable communication hub of claim 1, wherein the connected device comprises an edge device operably coupled to the selected IRCP, and the operations further comprise: A preconfigured virtual address is automatically associated with a device address of the edge device such that the edge device is referenced by the preconfigured virtual address.

3. The dynamically reconfigurable communication hub of claim 1, wherein the communication profile comprises a ModbusTCP protocol.

4. The dynamically reconfigurable communication hub of claim 1, wherein the communication profile comprises protocol.

5. The dynamically reconfigurable communication hub of claim 1, wherein the communication profile comprises an MQTT protocol.

6. The dynamically reconfigurable communication hub of claim 1, wherein the communication profile comprises a TCP / IP protocol.

7. The dynamically reconfigurable communication hub of claim 1, wherein: After receiving the reconfiguration signal, the operation further includes: A script thread executing on the processor is interrupted and an action is caused at the interrupted thread.

8. The dynamically reconfigurable communications hub of claim 1, wherein the connected device comprises a master controller device and the operations further comprise configuring the selected IRCP as a master port.

9. The dynamically reconfigurable communication hub of claim 1, wherein the connected device is connected to an edge device via an in-line converter, the in-line converter being configured to convert an incompatible signal from the edge device into a signal that is compatible with the dynamically reconfigurable communication hub.

10. The dynamically reconfigurable communication hub of claim 1, wherein: When the selected IRCP is configured in the master mode, the selected IRCP is configured to initiate operations in the connected device.

11. The dynamically reconfigurable communication hub of claim 10, wherein: Initiating an operation in the connected device includes initiating a read operation in the connected device.

12. The dynamically reconfigurable communication hub of claim 10, wherein: Initiating an operation in the connected device includes initiating a write operation in the connected device.

13. A computer-implemented method (2600) executed by at least one processor for automatically and independently configuring independent reconfigurable connection ports (IRCPs), the method comprising: Receiving a reconfiguration signal at the IRCP (2605); retrieving from a first data store a first predetermined set of rules for identifying a communication profile of the IRCP based on the reconfiguration signal, wherein the communication profile comprises an operating mode and a communication protocol (2610), wherein the operating mode comprises a master mode, a slave mode, and a pass-through mode; identifying an operating mode of the IRCP based on the first predetermined rule set (2615), wherein the IRCP is configured to: at least one of a master port, a slave port, and a pass-through port based on the first predetermined rule set; identifying a communication protocol with the IRCP based on a second predetermined set of rules (2620); generating a configuration profile based on the operating mode and the communication protocol (2625); and, An association between the configuration profile and the IRCP is stored in a second data store.

14. The computer-implemented method of claim 13, wherein the reconfiguration signal is received from an edge device operably coupled to the IRCP, the method further comprising: automatically associating a preconfigured virtual address with a device address of the edge device such that the edge device is referenced by the preconfigured virtual address; as well as, A configuration profile associated with the IRCP is updated with an association between the preconfigured virtual address and the device address.

15. The computer implemented method of claim 13, wherein the reconfiguration signal is received from a master controller device, and the method further comprises configuring the IRCP as a master port.

16. The computer implemented method of claim 13, wherein the communication profile comprises a Modbus TCP protocol.

17. The computer-implemented method of claim 13, wherein the communication profile comprises protocol.

18. The computer-implemented method of claim 13, wherein the communication profile comprises an MQTT protocol.

19. The computer implemented method of claim 13, wherein the communication profile comprises a TCP / IP protocol.

20. A distributed communication and control system (100), comprising: at least one edge device (105); and, A first dynamically reconfigurable communication hub (155) comprising a plurality of independently reconfigurable connection ports (IRCPs) (1920, 1925, 1930, 1935) and operably coupled to the at least one edge device, wherein the dynamically reconfigurable communication hub is configured to perform an automatic reconfiguration operation to independently configure each of the plurality of IRCPs, the operation comprising: receiving, at an IRCP among the plurality of IRCPs, a communication signal from an edge device among the at least one edge device; determining the selected IRCP to be reconfigured; retrieving from a first data store a first predetermined rule set (1835) for identifying a communication profile (1917) of the selected IRCP based on the received communication signal and a second rule set (1840) for associating the communication profile with the selected IRCP, wherein the communication profile includes an operating mode and a communication protocol (1825); identifying a communication profile of the selected IRCP based on the first predetermined rule set; associating the communication profile with the selected IRCP based on a second predetermined rule set (1840), the second predetermined rule set configured to independently associate the identified communication profile with one of the plurality of IRCPs such that no user intervention is required in configuring the plurality of IRCPs; updating in the data store an association in a configuration profile associated with the IRCP; and A preconfigured virtual address is automatically associated with a device address of the at least one edge device such that the at least one edge device is referenced by the preconfigured virtual address.

21. The distributed communication and control system of claim 20, further comprising a second dynamically reconfigurable communication hub, wherein the first dynamically reconfigurable communication hub and the second dynamically reconfigurable communication hub are operably coupled via a control network.

22. The distributed communication and control system of claim 21, wherein the control network comprises a Modbus network.

23. The distributed communication and control system of claim 20, further comprising an in-line converter coupled in series to the edge device and the first dynamically reconfigurable communication hub, in: The at least one edge device comprises an incompatible device configured to generate an incompatible signal, and, The in-line converter is configured to convert the incompatible signal into a compatible signal for the first dynamically reconfigurable communication hub.

24. The distributed communication and control system of claim 23, wherein the incompatible signal comprises an analog signal.

25. The distributed communication and control system of claim 23, wherein the incompatible signal comprises a discrete signal.

26. The distributed communication and control system of claim 23, wherein the compatible signal comprises an IO-Link signal.

27. The distributed communication and control system of claim 20, wherein the at least one edge device comprises an indicator device.

28. The distributed communication and control system of claim 20, wherein the at least one edge device comprises an actuator.

29. The distributed communication and control system of claim 20, wherein the at least one edge device comprises a motor.

30. The distributed communication and control system of claim 20, wherein the at least one edge device comprises an IO-Link sensor.

31. The distributed communication and control system of claim 20, wherein the at least one edge device comprises an IO-Link input device.

32. The distributed communication and control system of claim 20, wherein the at least one edge device comprises a robotic device.

33. The distributed communication and control system of claim 20, wherein the at least one edge device comprises a sensor.

34. The distributed communication and control system of claim 20, wherein the first dynamically reconfigurable communication hub is connected to a remote computer device via a communication network, wherein a configuration signal is received from the remote computer device via the communication network.

35. A communication hub comprising: a plurality of independently reconfigurable connection ports (IRCPs) (1920, 1925, 1930, 1935), each of the plurality of IRCPs being reconfigurable as at least one of a master port, a slave port, and a pass-through port; A memory module (1915) comprising at least an interrupt instruction program (1911) and a script instruction program (1912); a processor (1910) operably coupled to the memory module and configured to execute the interrupt instruction program and the script instruction program; a shared data register (1916) configured to be accessible via the processor; as well as, A data storage device storing a plurality of configuration profiles (1917) such that, When the interrupt instruction program and the script instruction program are executed, one of the plurality of configuration profiles is identified and applied, so that, Upon receiving an input signal from a connected device coupled to one of the plurality of IRCPs, based on the applied configuration profile, the processor performs: (a) the interrupt instruction program to execute dedicated logic including predetermined rules, wherein the dedicated logic includes simultaneous and parallel operation at each of the plurality of IRCPs, wherein the dedicated logic includes storing data corresponding to the input signal in the shared data register, and configuring the plurality of IRCPs, as well as, (b) The script instruction program is used to identify the shared data register associated with the input signal and generate an output signal at one or more of the multiple IRCPs based on the data stored in the shared data register, thereby providing simultaneous control operation at the multiple IRCPs.

36. The communication hub of claim 35, wherein the plurality of IRCPs are each configurable to be operably coupled to a Modbus network.

37. The communication hub of claim 35, wherein the plurality of IRCPs are each configurable to be operably coupled to an IO-Link network.

38. The communication hub of claim 35, wherein the shared data registers are configurable to be globally accessible by the plurality of IRCPs and the processor.

39. The communication hub of claim 35, wherein the shared data register is configured to store 16 bits of data.

40. The communication hub of claim 35, wherein the shared data register is configured to store 32 bits of data.

41. A communication hub according to claim 35, wherein the memory module includes multiple protocol profiles, each protocol profile corresponds to an IRCP among the multiple IRCPs, wherein for the corresponding IRCP, each protocol profile includes rules and operations to be executed by the interrupt instruction program and the script instruction program.

42. The communication hub of claim 35, wherein: The connected device comprises an incompatible device configured to generate an incompatible signal, and, The communication hub is serially connected to the incompatible device through an inline converter, wherein the inline converter is configured to convert the incompatible signal into a compatible signal using at least one configuration profile of the plurality of configuration profiles.

43. The communication hub of claim 42, wherein the incompatible signal comprises an analog signal.

44. The communication hub of claim 42, wherein the incompatible signal comprises a discrete signal.

45. The communication hub of claim 42, wherein the compatible signal comprises an IO-Link signal.

46. ​​The communication hub of claim 35, wherein the connected device comprises an indicator device.

47. The communications hub of claim 35, wherein the connected device comprises an actuator.

48. The communication hub of claim 35, wherein the connected device comprises a motor.

49. The communication hub of claim 35, wherein the connected device comprises an IO-Link sensor.

50. The communication hub of claim 35, wherein the connected device comprises an IO-Link input device.

51. The communication hub of claim 35, wherein the connected device comprises a robotic device.

52. The communication hub of claim 35, wherein the connected device comprises a sensor.

53. A communication hub according to claim 35, wherein each of the plurality of configuration profiles includes a rule set, which, when applied to one of the plurality of IRCPs, causes the processor to access and process data in the shared data register and generate a signal at the applied IRCP.

54. The communication hub of claim 35, wherein: The script instruction program is configured to generate a trigger signal to the processor, wherein upon receiving the trigger signal, the processor executes the interrupt instruction program, the interrupt instruction program comprising: identifying a shared data register based on the triggering signal; retrieving data stored in the identified shared data register from the identified virtual address; and, The output signal is generated at one or more of the plurality of IRCPs based on the retrieved data.

55. The communication hub of claim 35, wherein configuring the plurality of IRCPs comprises: retrieving from a first data store a first set of predetermined rules for identifying a communication profile of the IRCP based on the input signal and a second set of predetermined rules for associating the communication profile with the IRCP, wherein the communication profile includes an operating mode and a communication protocol, identifying a communication profile of a corresponding IRCP based on said first predetermined rule set, and, Based on the second predetermined set of rules, the identified operating mode and communication protocol are associated with the IRCP.

56. A communication hub according to claim 35, wherein the output signal is configured to be generated at one IRCP among the multiple IRCPs that is coupled to a target device referenced by a preconfigured virtual address, and wherein the script instruction program includes automatically associating the preconfigured virtual address with the device address of a newly connected device when the newly connected device is coupled to one of the multiple IRCPs, so that the newly connected device is referenced by the preconfigured virtual address.

57. A computer-implemented method (2500) executed by at least one processor to process communication signals at an independently reconfigurable connection port (IRCP), the method comprising: receiving an input signal from a connected device at one of the IRCPs (2505); identifying a next operation (2515) based on a configuration profile (1917) associated with the IRCP receiving the input signal; When it is determined that the next operation is a write operation (2530), the data corresponding to the input signal is stored in a shared data register (2535); When it is determined that the next operation is a configuration operation (2555), the IRCP is reconfigured based on a predetermined set of rules, wherein the configuration operation includes: retrieving from a first data store a first predetermined rule set for identifying a communication profile of the IRCP based on the input signal and a second predetermined rule set for associating the communication profile with the IRCP, wherein the communication profile includes an operating mode and a communication protocol (2610); identifying a communication profile of a corresponding IRCP based on the first predetermined rule set (2615); and, associating the identified operating mode and communication protocol with the IRCP based on the second predetermined rule set (2625); and, When it is determined that the next operation is a read operation (2540), a shared data register associated with the input signal is identified (2545), and an output signal is generated in at least one of the IRCPs based on data stored in the shared data register (2550).

58. The computer-implemented method of claim 57, wherein: Storing data corresponding to the input signal in a shared data register comprises: identifying a device address according to the input signal, wherein the device address is an identifier of an edge device that sends the input signal; determining a virtual address of the shared data register based on the IRCP corresponding to the input signal, and, Data corresponding to the input signal is stored in the shared data register at the virtual address.

59. The computer implemented method of claim 57, wherein the input signal is received via a Modbus network.

60. The computer implemented method of claim 57, wherein the input signal is received via an IO-Link network.

61. The computer implemented method of claim 57, wherein the input signal is received via a Modbus network.

62. The computer-implemented method of claim 57, wherein the input signal is received from a remote computer device via Ethernet.

63. The computer-implemented method of claim 57, wherein the connected device comprises a pointing device.

64. The computer implemented method of claim 57, wherein the connected device comprises an actuator.

65. The computer implemented method of claim 57, wherein the connected device comprises a motor.

66. The computer implemented method of claim 57, wherein the connected device comprises an IO-Link sensor.

67. The computer implemented method of claim 57, wherein the connected device comprises an IO-Link input device.

68. The computer-implemented method of claim 57, wherein the connected device comprises a robotic device.

69. The computer-implemented method of claim 57, wherein the connected device comprises a sensor.

70. A computer-implemented method according to claim 57, wherein the next action is identified based on the configuration profile and rules defined in a rule-based engine associated with the IRCP, wherein the rule-based engine is user configurable to provide edge processing of data received from the connected device.

71. The computer-implemented method of claim 70, wherein: The rule-based engine is configured to cause the at least one processor to execute a predetermined program of a user-configurable user rule profile, wherein the user rule profile is configurable in a spreadsheet-style interface.

72. The computer implemented method of claim 57, wherein the operating modes include a master mode, a slave mode, and a pass-through mode.

73. A distributed communication and control system (100), comprising: at least one edge device (105); as well as, A first dynamically reconfigurable communication hub (155) comprising: a plurality of independently reconfigurable connection ports (IRCPs) (1920, 1925, 1930, 1935) configured to be reconfigurable into at least one of a master port, a slave port, and a pass-through port; A memory module (1915) comprising at least an interruption instruction program (1911) and a script instruction program (1912); a processor (1910) operably coupled to the memory module and configured to execute the interrupt instruction program and the script instruction program; a shared data register (1916) configured to be accessible via the processor; and, A data storage device storing a plurality of configuration profiles (1917) such that, When the interrupt instruction program and the script instruction program are executed, at least one configuration profile of the plurality of configuration profiles is identified and applied, so that, Upon receiving an input signal from one of the plurality of IRCPs, based on the applied configuration profile, the processor performs: (a) the interrupt instruction program to execute dedicated logic including predetermined rules, wherein the dedicated logic includes simultaneous and parallel operation at each of the plurality of IRCPs, wherein the dedicated logic includes storing data corresponding to the input signal in the shared data register and configuring the plurality of IRCPs, as well as, (b) the script instruction program to identify a shared data register associated with the input signal and generate an output signal at one or more of the plurality of IRCPs based on data stored in the shared data register, thereby providing simultaneous control operation at the plurality of IRCPs.

74. The distributed communication and control system of claim 73, wherein said operations further comprise: A preconfigured virtual address is automatically associated with a device address of the at least one edge device such that the at least one edge device is referenced by the preconfigured virtual address.

75. The distributed communication and control system of claim 73, further comprising a second dynamically reconfigurable communication hub, wherein the first dynamically reconfigurable communication hub and the second dynamically reconfigurable communication hub are operably coupled via a control network.

76. The distributed communication and control system of claim 73, further comprising an in-line converter coupled in series to the edge device and the first dynamically reconfigurable communication hub, in: The at least one edge device comprises an incompatible device configured to generate an incompatible signal, and, The in-line converter is configured to convert the incompatible signal into a compatible signal.

77. A distributed communication and control system according to claim 76, wherein the incompatible signal comprises an analog signal.

78. A distributed communication and control system as described in claim 76, wherein the incompatible signal comprises a discrete signal.

79. The distributed communication and control system of claim 76, wherein the compatible signal comprises an IO-Link signal.

80. The distributed communication and control system of claim 73, wherein the at least one edge device comprises an indicating device.

81. The distributed communication and control system of claim 73, wherein at least one of the edge devices comprises an actuator.

82. The distributed communication and control system of claim 73, wherein the at least one edge device comprises a motor.

83. The distributed communication and control system of claim 73, wherein the at least one edge device comprises an IO-Link sensor.

84. The distributed communication and control system of claim 73, wherein the at least one edge device comprises an IO-Link input device.

85. The distributed communication and control system of claim 73, wherein at least one of the edge devices comprises a robotic device.

86. The distributed communication and control system of claim 73, wherein the at least one edge device comprises a sensor.

87. A distributed communication and control system according to claim 73, wherein the first dynamically reconfigurable communication hub is connected to a remote computer device via a communication network, wherein the configuration signal is received from the remote computer device via the communication network.

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