Customized integrated IO system

Abstract

The application relates to the technical field of industrial control and electronic integration, and provides a customized integrated IO system, which comprises a shell, a backboard, a plurality of functional PCBAs, a main control unit, a coupler and an external interface assembly; the backboard is provided with a power supply bus, a communication bus, a plurality of standardized mounting positions and correspondingly arranged board-to-board connectors; the plurality of functional PCBAs are respectively assembled in the corresponding standardized mounting positions, are electrically connected with the backboard through the corresponding board-to-board connectors to access the power supply bus and the communication bus, are arranged in a direction parallel to the backboard, and are independently fixed to the backboard through fasteners; and the main control unit performs data interaction with the functional PCBAs through the communication bus. The plurality of functional PCBAs are integrated in the same backboard in parallel, access the power supply bus and the communication bus through the corresponding board-to-board connectors, and the problems of communication signal attenuation, transmission delay accumulation and single module fault affecting downstream modules caused by module-level serial transmission in the existing distributed IO system are reduced.

Description

Technical Field

[0001] This invention relates to the field of industrial control and electronic integration technology, and in particular to a customized integrated IO system suitable for industrial automation control, equipment signal acquisition and output, distributed control units, dedicated controllers and other scenarios. Background Technology

[0002] In industrial automation control, equipment signal acquisition and output, and dedicated controller scenarios, I / O systems are typically used to enable signal interaction between the controller and field sensors, digital input devices, analog input devices, or actuators. Existing distributed I / O systems generally consist of multiple independent modules such as couplers, power supply modules, DI / DO modules, and AI / AO modules. These modules are typically connected sequentially via guide rails, snap-fit ​​mechanisms, slides, or lateral connectors, and power and communication signals are transmitted through inter-module connection structures.

[0003] However, existing distributed I / O systems mostly employ a module-in-series or chain topology. Power supply and communication signals between modules need to be passed cascaded through each stage. As the number of modules increases, signal attenuation is common. If an intermediate module becomes loose, has poor contact, or malfunctions, downstream modules will also be affected. Individual modules need to be fixed to the guide rail using spring clips, and modules are then aligned with each other using sliding grooves or lateral structures. Under vibration or impact, displacement or tension can easily occur, leading to decreased assembly reliability. Furthermore, the overall length increases when multiple modules are connected in series, limiting on-site installation space. Maintenance often requires disassembling upstream modules before accessing downstream modules, making the process cumbersome.

[0004] Furthermore, while existing integrated I / O modules can concentrate some input / output functions into a single housing, their interfaces and channels are typically fixed, making flexible configuration impossible based on application scenarios. If multiple combinations of functions, such as digital input, digital output, analog input, and analog output, are required simultaneously, multiple modules of different models often still need to be spliced ​​together, increasing system connection points and costs while also reducing maintenance convenience. Summary of the Invention

[0005] To address the problems of poor communication cascading reliability, complex assembly, weak vibration resistance, and inconvenient maintenance in existing distributed I / O systems, as well as the fixed functions and difficulty in customization of existing integrated I / O modules, this invention proposes a customized integrated I / O system suitable for high-vibration environments. This system achieves parallel access to multiple functional PCBAs through a unified backplane bus, and uses an integrated packaging structure where each functional PCBA is independently fixed to the backplane. This provides configurable I / O functional resources within a fixed form factor, balancing communication reliability, structural stability, vibration resistance, maintenance convenience, and functional adaptability. The objectives of this invention can be achieved through the following technical solutions: This application provides a customized integrated IO system, including a housing, a backplane, a multi-functional PCBA, a main control unit, a coupler, and external interface components; The backplate is fixedly installed inside the housing. The backplate is equipped with a power supply bus, a communication bus, multiple standardized mounting positions, and board-to-board connectors corresponding to each standardized mounting position. Multiple functional PCBAs are respectively assembled in corresponding standardized mounting positions and electrically connected to the backplane through corresponding board-to-board connectors to access the power supply bus and communication bus; Each functional PCBA is arranged in a direction parallel to the back panel and is independently fixed to the back panel by fasteners; The main control unit interacts with each functional PCBA via a communication bus; The external interface components are located on the outside of the housing and are electrically connected to each functional PCBA to bring out the input and output signals of each functional PCBA. With a fixed housing size, the IO system can form one or more functions such as digital input, digital output, analog input and analog output by assembling different types of functional PCBAs on standardized mounting positions and / or configuring the functional PCBAs. The IO system also includes a control signal link independent of the communication bus. The main control unit sends control signals to multiple functional PCBAs through a coupler. The coupler serves as the physical sender and receiver of the control signal link. Each functional PCBA is connected to the control signal link in a predetermined order. Each functional PCBA is equipped with a control path switching structure. The control path switching structure is used to return the control signal to the coupler along the feedback path when no next functional PCBA is detected after the current functional PCBA, thus forming a closed-loop control path.

[0006] Furthermore, both the power supply bus and the communication bus are located on the backplane, allowing any functional PCBA to connect to the power supply bus and the communication bus through the corresponding board-to-board connector, obtain operating power from the power supply bus, and interact with the main control unit through the communication bus.

[0007] Furthermore, each standardized mounting position has the same mechanical mounting dimensions and basic electrical interface definition, which includes at least a power supply interface and a communication interface, so that different types of functional PCBAs can be assembled in any standardized mounting position.

[0008] Furthermore, each board-to-board connector has at least a power pin group, a ground pin group, a communication pin group, and an identification pin group. The power pin group serves as the pins of the power supply interface and is electrically connected to the power supply bus to provide operating power to the corresponding functional PCBA. The ground pin group is electrically connected to the ground network on the backplane to provide grounding connection to the functional PCBA. The communication pin group serves as the pins of the communication interface and is electrically connected to the communication bus to complete data interaction between the corresponding functional PCBA and the main control unit. The identification pin group is used to transmit identification information of the corresponding functional PCBA type.

[0009] Furthermore, each functional PCBA is equipped with an identification circuit or storage unit to store the type information of the corresponding functional PCBA. The main control unit reads the type information of the functional PCBA through the identification pin group and establishes the corresponding channel function mapping relationship based on the type information. The channel function mapping relationship is the correspondence between the standardized mounting position, the functional PCBA type, the channel number of the functional PCBA, and the input and output functions of the corresponding channel.

[0010] Furthermore, each functional PCBA is equipped with a module control unit and a control path switching unit. Each functional PCBA is connected to the control signal link in sequence according to the assembly order on the backplane. The transmission path of the control signal link is a ring topology formed by outputting through the coupler, being transmitted sequentially through each functional PCBA, and being transmitted back to the coupler through the end functional PCBA. The module control unit is used to receive control signals and perform status control or status detection on the functional PCBA; The control path switching unit is controlled by a switch control signal and has a first path and a second path. The first path is used to output the control signal to the next functional PCBA, and the second path is used to conduct the control signal to the return path to return to the coupler.

[0011] Furthermore, each functional PCBA is equipped with a connection detection unit for detecting whether there is a next functional PCBA in the subsequent stage of the current functional PCBA. The connection detection unit is electrically connected to the control path switching unit. The connection detection unit generates a detection result based on the connection status of the next functional PCBA. The module control unit generates a switch control signal based on the detection result and controls the control path switching unit to open the first or second path through the switch control signal. Specifically, when the connection detection unit detects the existence of the next functional PCBA, the module control unit generates a first switch control signal to open the first path of the control path switching unit so that the control signal is transmitted to the next functional PCBA. When the connection detection unit does not detect the existence of the next functional PCBA, the module control unit generates a second switch control signal, or the control path switching unit remains in the default state and opens the second path so that the control signal returns to the coupler via the feedback path.

[0012] Furthermore, the connection detection unit includes one or more of the following: detection pins, short-circuit identification loops, resistance identification networks, or level detection circuits disposed between adjacent functional PCBAs.

[0013] Furthermore, the second path is the default conducting path, and the control path switching unit defaults to conducting the second path after power-on. When the connection detection unit does not detect the existence of the next functional PCBA, the detection result is abnormal, or the current functional PCBA is in the power-on initialization state, the module control unit generates a second switch control signal, or the control path switching unit maintains the default state, maintains or switches to the second path, and makes the current functional PCBA, as the end functional PCBA, send the control signal back to the coupler. When the connection detection unit detects the existence of the next functional PCBA, and the module control unit generates a valid first switch control signal, the control path switching unit switches from the second path to the first path so that the control signal is transmitted to the next functional PCBA.

[0014] Furthermore, the control path switching unit includes one of an analog switch, a relay switch, a digital multiplexer, or a transistor conduction network, used to connect the first path or the second path according to the detection result of the connected detection unit or the control signal of the module control unit.

[0015] Furthermore, the coupler or main control unit is equipped with a closed-loop integrity detection unit to monitor the control signal returned to the coupler via the feedback path. It determines the closed-loop integrity of the control signal link based on whether a control signal is received. Specifically, if the coupler receives a control signal within a preset time window, the closed-loop of the control signal link is considered complete. Otherwise, if the coupler does not receive the feedback control signal or the signal is abnormal, the control signal link is considered disconnected, has a contact abnormality, or a switching abnormality. Specifically, a disconnected link occurs when the control signal fails to reach the coupler at a certain functional PCBA or connector; a contact abnormality occurs when the feedback control signal reaches the coupler, but the signal level or waveform is abnormal, indicating potential poor contact at the functional PCBA connector or solder joint; and a switching abnormality occurs when the encoding or pulse characteristics of the feedback signal are inconsistent with the preset end-switching logic, indicating that the control path switching unit has not correctly connected the feedback path.

[0016] Furthermore, the closed-loop integrity detection unit is also used to acquire the feedback parameters of the control signal returned to the coupler. These feedback parameters include one or more of the following: feedback arrival time, feedback level status, feedback pulse width, and feedback encoding information. Based on the feedback parameters and preset judgment conditions, the unit determines the location of the end functional PCBA of the control signal link, the number of connected functional PCBAs, or the link connectivity status. The preset judgment conditions include one or more of the following: time judgment conditions, level judgment conditions, pulse width judgment conditions, and encoding judgment conditions. Time judgment conditions limit the allowable time range between the control signal being emitted from the coupler and its return to the coupler, such as a preset minimum return time, a preset maximum return time, or multiple return time intervals corresponding to different numbers of functional PCBAs. Level judgment conditions limit the effective level state of the returned control signal, such as the returned signal should maintain a preset high level, a preset low level, or a preset level change sequence. Pulse width judgment conditions limit the duration range of effective pulses in the returned control signal. Encoding judgment conditions limit whether the module number, location number, quantity number, or verification information carried in the returned control signal conforms to a preset encoding format.

[0017] During the judgment process, the closed-loop integrity detection unit records the transmission time when the coupler sends a control signal and the reception time when the coupler receives the returned control signal. It then calculates the return arrival time based on the transmission and reception times. When the return arrival time falls within a preset time window, and the return level state, return pulse width, or return encoding information meets the corresponding preset judgment conditions, the control signal link is determined to be in a connected state. Conversely, if no return control signal is received within the preset time window, or if any parameter among the return level state, return pulse width, or return encoding information does not meet the preset judgment conditions, the control signal link is determined to be disconnected, have an abnormal contact, or have an abnormal control path switching.

[0018] To determine the location of the end-function PCBA, the closed-loop integrity detection unit can identify the current PCBA that is guiding the control signal to the return path based on the location number or module number in the return encoding information, and designate this PCBA as the end-function PCBA; alternatively, it can determine the number of PCBA stages the control signal passes through based on the correspondence between the return arrival time and a preset time interval, and determine the location of the end-function PCBA accordingly. To determine the number of connected PCBAs, the closed-loop integrity detection unit can determine the number of connected PCBAs in the current control signal link based on the quantity number in the return encoding information, the count information superimposed when the control signal passes through each PCBA, or the correspondence between the return arrival time and the preset number of stages. To determine the link connectivity status, the unit judges whether a return control signal has been received and whether the return parameters meet preset judgment conditions. If the conditions are met, the link connectivity is considered normal; if the conditions are not met, the link is considered abnormal.

[0019] Furthermore, each functional PCBA is arranged at intervals along the same side of the back panel. Each functional PCBA is fixed to the back panel by at least two fasteners located on both sides of the corresponding board-to-board connector. The housing and / or the back panel are provided with limiting structures that cooperate with the edges of the functional PCBAs. The limiting structures include a stop, a limiting rib or a limiting step that abuts against the edge of the functional PCBA, and / or a positioning post that cooperates with the positioning hole on the functional PCBA, so as to limit the lateral displacement of the functional PCBA relative to the back panel.

[0020] Furthermore, at least one functional PCBA is provided with a channel configuration circuit, which includes at least one or more of hardware jumper units, DIP switches, analog switches, and relays; the hardware jumper units or DIP switches are used to generate the hardware configuration status of the corresponding channel, such as determining whether a channel is a digital input, digital output, analog input, or analog output type; the analog switches or relays are used to switch the input and output signal paths of the corresponding channel to realize the on / off or direction control of different signals; During system operation, the main control unit reads the configuration parameters corresponding to the channel configuration circuit and controls the corresponding channel to perform digital input, digital output, analog input, or analog output functions according to the configuration parameters. The configuration parameters include the channel function type determined by the hardware configuration state and / or the channel connection state determined by the input / output signal path. This allows the same functional PCBA to have its functions predefined based on hardware jumpers or DIP switches, while simultaneously switching signal paths via analog switches or relays. This enables flexible channel-level configuration and multi-functional multiplexing, meeting the needs of different application scenarios and allowing for various combinations of digital and analog input / output without replacing the board.

[0021] Compared with the prior art, the present invention has the following advantages: This application integrates multiple functional PCBAs in parallel on the same backplane, and connects each functional PCBA to the power supply bus and communication bus respectively via corresponding board-to-board connectors. This reduces the communication signal attenuation, transmission delay accumulation, and the impact of a single module failure on downstream modules caused by module-level serial transmission in existing distributed I / O systems, thereby improving system communication reliability. Simultaneously, each functional PCBA is arranged parallel to the backplane and independently fixed to it using fasteners. With integrated housing packaging and limiting structure, it reduces assembly instability caused by mutual pulling between modules, loosening of slides or failure of snaps in existing series modules, thereby improving assembly reliability, overall structural stability and vibration and shock resistance.

[0022] Furthermore, the system can achieve various I / O function combinations such as digital input, digital output, analog input, and analog output by assembling different types of functional PCBAs and / or configuring channels within a fixed housing size. This reduces the fault points and costs associated with using multiple modules in series. Moreover, by setting up control path switching structures in each functional PCBA that are linked to the connection status of subsequent stages, the control signal continues to be transmitted when a next functional PCBA is present, and returns to the coupler via a feedback path when no next functional PCBA is present. This automatically forms a closed-loop control path, allowing the system to complete control link construction, end-point identification, and closed-loop integrity detection without requiring manual specification of end modules or complex configurations. This improves the system's configuration flexibility, fault diagnosis capabilities, and on-site maintenance convenience. Attached Figure Description

[0023] Figure 1 This is an exploded view of the customized integrated I / O system in an embodiment of the present invention, wherein... Figure 1 (a) in the figure is an exploded view of the main components of the system. Figure 1 (b) in the figure is a three-dimensional exploded view of the system; Figure 2 This is a schematic diagram of the backplate structure and standardized mounting position in an embodiment of the present invention, wherein... Figure 2 (a) in the diagram is a schematic diagram of the back plate structure. Figure 2 (b) is a schematic diagram of the coupler after it has been assembled with the backplate. Figure 2 (c) is a schematic diagram of the structure after multiple functional PCBAs are assembled on the backplane; Figure 3 This is an external view of the customized integrated I / O system in an embodiment of the present invention, wherein, Figure 3 (a), (b), and (c) in the figure are the appearance structure diagrams from the first, second, and third perspectives, respectively. Figure 4 This is a schematic diagram of the control topology of the customized integrated I / O system in an embodiment of the present invention; Figure 5 This is a closed-loop control mechanism diagram based on automatic switching of the subsequent connection state in an embodiment of the present invention.

[0024] The attached figures are labeled as follows: 1: Housing; 11: Bottom housing; 12: Top housing; 2: Backplate; 3: Fasteners; 4: Couplers; 5: External interface components; 6: Standard modules; 7: Board-to-board connectors; 8: Standardized mounting positions. Detailed Implementation

[0025] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the following embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. All equivalent substitutions, improvements, or modifications made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0026] It should be noted that in the description of this invention, terms such as "upper," "lower," "inner," "outer," "left," "right," "front," and "rear," etc., are merely descriptions based on the orientation relationships shown in the accompanying drawings to facilitate the description of this invention and simplify the explanation, and are not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0027] Furthermore, the various embodiments and technical features in these embodiments can be combined with each other, provided there is no conflict.

[0028] In existing distributed I / O systems, multiple I / O modules are typically connected sequentially via external splicing. Couplers, power supply modules, digital input modules, digital output modules, analog input modules, and analog output modules are each mounted as independent housing modules on a DIN rail, transmitting power and communication signals through lateral connections between adjacent modules. This structure is characterized by clear module types and intuitive expansion methods, allowing users to add different types of modules according to site requirements. However, since both power supply and communication rely on hierarchical transmission between modules, the more modules there are, the more connection nodes there are, and the longer the signal path. If an intermediate module becomes loose, has poor contact, or malfunctions, the power supply and communication of downstream modules may be affected. Furthermore, the connections between multiple modules rely on slots, clips, or spring contacts. Under vibration, impact, or long-term operating conditions, problems such as module displacement, unstable spring contacts, and connector loosening can easily occur, leading to a decrease in system reliability.

[0029] While existing integrated I / O modules can concentrate multiple input / output interfaces within a single housing, reducing the number of external modules required, the number of interfaces, channel types, and functional combinations are typically fixed during the product design phase. For example, one module might only support a fixed number of digital inputs, while another might only support a fixed number of analog inputs or outputs. When actual projects require the simultaneous combination of multiple functions such as DI, DO, AI, and AO, multiple different module models still need to be selected, or a dedicated module needs to be redesigned. This not only increases product model and on-site selection costs but also makes it difficult to accommodate multiple functional combinations within a fixed form factor. Therefore, existing technologies either tend towards external serial expansion, leading to cascade reliability and vibration resistance issues, or they tend towards fixed function integration, resulting in fixed functions and insufficient customization capabilities, making it difficult to simultaneously address miniaturization, reliability, vibration resistance, maintenance convenience, and functional configurability.

[0030] To address the aforementioned issues, this application provides a customized integrated I / O system. Instead of continuously connecting multiple independent I / O modules in series outside the housing, it incorporates a backplane within the same housing. This backplane features multiple standardized mounting positions and corresponding board-to-board connectors, allowing multiple functional PCBAs to be individually mounted on the backplane and connected to its power and communication buses. This eliminates the reliance on adjacent modules for power and communication signal transmission, reducing signal attenuation, contact point accumulation, and the impact of intermediate module failures on downstream modules—problems common in traditional series structures. Furthermore, each functional PCBA is independently secured to the backplane with fasteners and positioned using limiting structures on the housing or backplane, preventing mechanical pulling and improving assembly stability and shock resistance in high-vibration environments.

[0031] Furthermore, this application does not merely fix multiple functional PCBAs within the same housing; rather, through standardized mounting positions, pin groups for identification, identification circuits or storage units, and channel configuration circuits, it enables the system to identify different types of functional PCBAs within a fixed housing size. It then establishes corresponding channel function relationships based on the functional PCBA type or channel configuration parameters, thereby forming one or more functional combinations of digital input, digital output, analog input, and analog output. In other words, this application achieves functional modularity and channel configurability within the housing, rather than relying on multiple external modules connected in series to meet functional combination requirements, as is present in existing technologies.

[0032] Furthermore, this application also establishes a control signal link independent of the communication bus. Each functional PCBA is sequentially connected to this control signal link according to its assembly order in the standardized mounting position, and a downstream presence detection structure and a control path switching structure are set in the functional PCBA. When the current functional PCBA detects the existence of a downstream functional PCBA, the control signal continues to be transmitted to the next functional PCBA; when the current functional PCBA does not detect the existence of a downstream functional PCBA, the control path switching structure conducts the control signal to the return path, so that the control signal returns to the coupler, forming a closed-loop control path. Through this structure, the system can automatically form a closed-loop control link according to the actual number of assembled functional PCBAs, without the need for manual specification of the end module, and without relying on complex software enumeration or address configuration to complete the end identification and closed-loop integrity detection. The specific implementation is as follows: like Figures 1 to 5 As shown, this embodiment provides a customized integrated IO system, including a housing 1, a backplane 2, a multi-functional printed circuit board assembly (PCBA), a main control unit, a coupler 4, and an external interface assembly 5.

[0033] The backplane 2 is fixedly installed inside the housing 1. The backplane 2 is provided with a power supply bus, a communication bus, multiple standardized mounting positions 8, and board-to-board connectors 7 corresponding to each standardized mounting position 8. Multiple functional PCBAs are respectively assembled in their corresponding standardized mounting positions 8 and electrically connected to the backplane 2 through their corresponding board-to-board connectors 7 to access the power supply bus and the communication bus. Each functional PCBA is arranged parallel to the backplane 2 and is independently fixed to the backplane 2 by fasteners 3. The main control unit is located inside the housing 1 and interacts with each functional PCBA through the communication bus. The external interface component 5 is located on the outside of the housing 1 and is electrically connected to each functional PCBA to bring out the input and output signals of each functional PCBA.

[0034] In this embodiment, each functional PCBA is arranged parallel to the back plate 2 and is independently fixed to the back plate 2 by fasteners 3 to constrain the displacement of each functional PCBA relative to the back plate 2. As a result, each functional PCBA is mechanically independent and does not rely on adjacent functional PCBAs for support or positioning, which can avoid the situation in the existing series-distributed structure where the loosening of a single module causes adjacent modules to be subjected to force, displacement or failure.

[0035] With a fixed external dimension of housing 1, the IO system can form one or more functions such as digital input, digital output, analog input and analog output by assembling different types of functional PCBAs on standardized mounting positions 8 and / or configuring the functions of the functional PCBAs, so as to meet the customized needs of different application scenarios.

[0036] In this embodiment, the housing 1 is preferably an integrated housing 1 structure. Specifically, the housing 1 may include a bottom shell 11 and a top shell, with the back plate 2 fixedly disposed inside the bottom shell 11. The bottom shell 11 and the top shell form an installation space for accommodating multiple functional PCBAs and the main control unit. By adopting an integrated housing 1 structure, the number of external splicing gaps and connection nodes in the split-type serial module scheme can be reduced, thereby improving the overall structural strength, assembly consistency, and environmental adaptability.

[0037] In this embodiment, both the power supply bus and the communication bus are located on the backplane 2. Each functional PCBA obtains its operating power from the backplane 2 through the corresponding board-to-board connector 7 and interacts with the main control unit through the backplane 2.

[0038] Unlike existing distributed I / O systems where power and communication signals are relayed sequentially through multiple modules, in this invention, each functional PCBA is connected to the power supply bus and communication bus on the backplane 2 in parallel. This reduces power transmission paths and communication relay nodes, minimizing voltage drop, signal attenuation, and transmission delay caused by cascading connections. Furthermore, a failure in any functional PCBA will not interrupt the power supply or communication links of other functional PCBAs, thus improving the overall system reliability.

[0039] In some alternative implementations, the communication bus may be a CAN bus, RS485 bus, SPI bus, I2C bus, or other data bus forms suitable for board-level communication; this invention is not limited to these. The power supply bus may provide single or multiple operating power supplies depending on different application scenarios, such as 5V, 12V, 24V, or other applicable voltage levels.

[0040] In this embodiment, each standardized mounting position 8 is provided with a uniform mechanical mounting size and a uniform basic electrical interface definition. The basic electrical interface definition includes at least a power supply interface and a communication interface, so that different types of functional PCBAs can be assembled in any standardized mounting position 8.

[0041] Specifically, each standardized mounting position 8 can have the same mounting hole positions, the same board outline boundaries, the same connector positions, and the same basic parts in the connector pin definitions. With the help of this standardized design, different types of functional PCBAs do not need to have their structural dimensions and basic interfaces designed separately for specific locations. They can be flexibly selected according to the actual needs of users, realizing platform-based, serialized, and modular development.

[0042] Furthermore, the pins of each board-to-board connector 7 include at least a power pin group, a ground pin group, a communication pin group, and an identification pin group. The identification pin group is used to transmit identification information that represents the corresponding functional PCBA type.

[0043] In this embodiment, each functional PCBA may be equipped with an identification circuit or storage unit to store the type information of the corresponding functional PCBA. The identification circuit or storage unit may employ a resistor-encoded circuit, read-only memory, EEPROM, Flash memory, dedicated identification chip, or other circuit forms capable of characterizing the board type. The main control unit can read the type information through the identification pin group and establish a corresponding channel function mapping relationship based on the type information. The type information may include, but is not limited to, board function type, number of channels, range parameters, input / output attributes, version information, and calibration parameters.

[0044] With the above settings, the main control unit can automatically identify the type of functional PCBA installed on each standardized mounting position 8 during system power-on or initialization, and automatically complete the corresponding channel resource allocation and function mapping, thereby reducing the workload of manual configuration and improving system deployment efficiency and ease of use.

[0045] In this embodiment, each functional PCBA is arranged at intervals along the same side of the back plate 2. Each functional PCBA is fixed to the back plate 2 by at least two fasteners 3 located on both sides of the corresponding board-to-board connector 7, so as to reduce the transmission of vibration load to the board-to-board connector 7.

[0046] Specifically, fastener 3 can be a combination of screws, studs and nuts, self-tapping screws, or other mechanical fastening structures suitable for fixing printed circuit boards. By directly fixing each functional PCBA to the backplane 2, the mechanical load on the board can be mainly transferred to the backplane 2 through the rigid fixing structure, rather than the board-to-board connector 7 bearing the main structural stress. This reduces the risk of connector loosening, poor contact, solder joint fatigue, etc., and improves the long-term stability of the electrical connection.

[0047] Furthermore, the housing 1 and / or the back plate 2 are provided with limiting structures that mate with the edges of the functional PCBA. The limiting structures are used to restrict the lateral displacement of the functional PCBA relative to the back plate 2. The limiting structures may be positioning grooves, limiting ribs, guards, bosses, or other suitable limiting components.

[0048] By cooperating with the fastener 3 and the limiting structure, the displacement of the functional PCBA in the vertical, lateral, and in-plane directions can be constrained, thereby effectively reducing the adverse effects of relative displacement and structural gaps of the boards under high vibration or impact conditions. Compared with existing distributed modules that use guide rail clips, slot embedding, or spring contact, each functional PCBA in this invention adopts an independent rigid fixing method, and there is no mechanical series dependency between them. Therefore, even if a single functional PCBA is disassembled or fails, it will not have a chain mechanical impact on other functional PCBAs, which is beneficial to improving the overall vibration and impact resistance and structural reliability of the machine.

[0049] In this embodiment, the housing 1 is an integrated housing 1, which includes a bottom shell 11 and a cover shell. The back plate 2 is fixed inside the bottom shell 11. The back plate 2 and the bottom shell 11 together form a load-bearing support structure for multiple functional PCBAs. The multiple functional PCBAs are installed in the accommodating space enclosed by the back plate 2 and the cover shell.

[0050] In a preferred embodiment, the backplate 2 can be mounted to the inner wall of the base shell 11 or to a pre-set mounting post by screws, riveting, snap-fitting, or other fixing methods. After multiple functional PCBAs are installed, the housing space is enclosed by the cover to form an integrated modular structure. This structure can reduce the direct impact of the external environment on the internal circuitry and is beneficial to improving overall protection performance and structural integrity.

[0051] Compared to existing distributed I / O systems, this invention employs an internal function reconfiguration method with a fixed housing size (1), eliminating the linear increase in overall product length due to the number of modules. Therefore, while meeting the needs of various I / O function combinations, it effectively controls the product's external dimensions, making it particularly suitable for space-constrained miniaturized device installation scenarios.

[0052] In one alternative embodiment, the outer dimensions of the housing 1 can be designed to be approximately 100mm × 30mm × 80mm. Of course, the above dimensions are merely examples, and the present invention is not limited thereto. Those skilled in the art can adjust the outer dimensions according to actual installation space, heat dissipation conditions, and the number of interfaces required, without affecting the basic concept of the present invention.

[0053] In this embodiment, the external interface component 5 includes multiple interface units, each of which includes at least one of a D-SUB connector and an M12 connector; each interface unit is electrically connected to a corresponding functional PCBA and is centrally located on the same side or two adjacent sides of the housing 1.

[0054] The D-SUB connector is suitable for multi-channel, high-density signal output, allowing for the integration of multiple input / output channels within a smaller panel space; the M12 connector is suitable for industrial field applications, offering good vibration resistance, loosening resistance, and environmental adaptability. Depending on the application scenario, one type of connector can be selected, or a combination of both can be used.

[0055] By centrally arranging multiple interface units on the same side or two adjacent sides of the housing 1, the overall external interface layout of the device can be made more organized, facilitating on-site wiring, installation, and maintenance. Compared with the existing distributed I / O systems where multiple separate modules are wired separately and connected module by module, this invention can reduce the complexity of on-site wiring, improve assembly efficiency, and reduce the risk of incorrect wiring.

[0056] In some implementations, the external interface component 5 can be connected to the corresponding functional PCBA via a wire harness, ribbon cable, adapter board, or direct plug-in method; this invention does not limit this. For applications with high protection requirements or significant vibration, industrial connectors with locking structures are preferred to further improve connection stability.

[0057] In this embodiment, at least one functional PCBA is provided with a channel configuration circuit. The channel configuration circuit includes at least one of a hardware jumper unit, a DIP switch, an analog switch, and a relay, and is used to configure the functions of at least some channels on the functional PCBA. The main control unit is used to read the configuration parameters corresponding to the channel configuration circuit and control the corresponding channel to perform digital input, digital output, analog input, or analog output according to the configuration parameters.

[0058] Specifically, in one implementation, the functional PCBA can be configured as a general-purpose functional board containing multiple reusable channels. The target function type corresponding to each channel can be predefined by setting hardware jumper units or DIP switches; alternatively, the input / output path, sampling path, or driving path of the channel can be reconstructed by controlling analog switches, relays, and other switching circuits through the main control unit. After reading the configuration parameters, the main control unit performs logical definition and resource allocation for the corresponding channels, enabling them to execute the corresponding DI, DO, AI, or AO functions.

[0059] For example, when a channel is configured as a digital input, it is connected to a digital sampling circuit to acquire switching signals or high / low level signals; when a channel is configured as a digital output, it is connected to a digital drive circuit to output switch control signals; when a channel is configured as an analog input, it is connected to an analog conditioning and sampling circuit to acquire voltage or current signals; when a channel is configured as an analog output, it is connected to a digital-to-analog converter and output drive circuit to output analog control signals.

[0060] Through the above methods, the present invention can not only achieve functional customization by replacing different types of functional PCBAs, but also reconfigure at least some channels within the same functional PCBA, thereby further improving the adaptability of a single product platform to different application requirements and reducing the number of product models and system failure nodes.

[0061] In this embodiment, the assembly process of the customized integrated I / O system may include the following steps: First, the back plate 2 is fixedly installed inside the bottom shell 11 of the housing 1; Secondly, install the main control unit in the preset position and establish a connection between it and the communication bus; Next, according to the target functional requirements, the corresponding type of functional PCBA is assembled on each standardized mounting position 8 and electrically connected to the backplane 2 through the corresponding board-to-board connector 7. Then, each functional PCBA is independently fixed to the backplate 2 using fasteners 3; Next, install the external interface component 5 and complete its electrical connection with each functional PCBA; Finally, the cover is assembled to form a complete integrated I / O system.

[0062] When the system requires maintenance, if a functional PCBA malfunctions, only the housing 1 needs to be opened and the corresponding fastener 3 removed to individually remove and replace the functional PCBA. This eliminates the need to sequentially disassemble other functional PCBAs or disconnect the upstream module before accessing the downstream module. After replacement, the main control unit can reread the identification information and / or configuration parameters of the functional PCBA and automatically update the corresponding channel mapping relationships. This significantly improves on-site repair efficiency and reduces maintenance complexity.

[0063] In one specific application embodiment, a control device needs to simultaneously implement 8 digital inputs, 8 digital outputs, 4 analog inputs, and 2 analog outputs within a limited installation space. When using the customized integrated I / O system of this invention, multiple standardized mounting positions 8 can be set within a fixed-size housing 1, and digital input function PCBAs, digital output function PCBAs, analog input function PCBAs, and analog output function PCBAs can be installed respectively; alternatively, one or more general-purpose function PCBAs with channel configuration circuits can be used, and the above functional combinations can be achieved through hardware configuration and main control unit software configuration.

[0064] After the system is powered on, the main control unit automatically identifies the type information and configuration parameters of each functional PCBA, establishes a corresponding channel mapping table, and then provides a unified signal interface to the outside world through the external interface component 5. Compared with the existing solution of connecting multiple separate IO modules in series to form the same function, the present invention can realize the required function in the same or smaller installation space, and has the advantages of fewer connection points, high reliability, strong vibration resistance, convenient maintenance, and neat interface layout.

[0065] Based on the above structural setup and operating method, this application integrates multiple functional PCBAs in parallel on the same backplane 2 and directly connects them to the power supply bus and communication bus via board-to-board connectors 7. This eliminates the module-level serial transmission structure in existing distributed I / O systems, thereby avoiding the problems of communication signal attenuation at each stage, transmission delay accumulation, and the impact of a single module failure on all downstream modules, significantly improving system communication reliability. Secondly, by independently fixing each functional PCBA to the backplane 2 and encapsulating them in an integrated housing 1, the assembly instability problems caused by mutual pulling between modules, loosening of slides, or failure of clips in existing serial modules can be avoided, thereby improving assembly reliability and overall structural stability. At the same time, by uniformly adopting a mounting method parallel to the backplane 2, a rigid fastening structure, and a limiting structure, the board mounting gap and vibration displacement can be reduced, the stress on the connectors can be reduced, and the system's adaptability to high vibration and shock environments can be improved.

[0066] Furthermore, by adopting standardized external interface components 5 such as D-SUB connectors and / or M12 connectors, wiring convenience is improved and on-site assembly difficulty is reduced. Simultaneously, since each function supports independent disassembly and assembly, point-to-point troubleshooting is possible during fault diagnosis, eliminating the need for sequential disassembly in series, thus improving maintenance efficiency. Moreover, by setting multiple standardized mounting positions 8 within a fixed-size housing 1, and allowing for the assembly of different types of functional PCBAs and / or flexible channel configuration, various IO function combinations can be achieved without altering the product's external form factor. This avoids the linear increase in overall length caused by the increase in the number of modules in existing distributed solutions, facilitating product miniaturization and standardization. By setting identification circuits or storage units and channel configuration circuits, automatic board type identification and flexible channel function definition are achieved. A single module integrates a multi-functional interface resource pool (DI / DO / AI / AO, etc.), and the actual functions are flexibly defined through hardware jumpers or software configuration. Diverse application needs can be met without the need for multiple modules in series, reducing system failure points, enhancing the adaptability of a single product platform to multi-scenario requirements, and achieving customized application effects for a single product with multiple functions.

[0067] Finally, in this application, by setting a control path switching structure linked to the connection status of the subsequent level in each sub-module, the control signal is transmitted to the subsequent level when a subsequent level module exists, and returned to the coupler 4 along the default path when a subsequent level module does not exist, automatically forming a closed-loop control link under different module number configurations. Through this structure, the system can complete the construction of the control link and end-point identification without preset module addresses, specifying end modules, or manually switching terminal states. This solution not only improves the flexibility of module expansion but also enhances assembly consistency, fault diagnosis capabilities, and on-site maintenance convenience. In this invention, after the coupler 4 sends a control signal to the first-level functional PCBA, the control signal is transmitted sequentially through each level of functional PCBA. When a certain level of functional PCBA does not detect the existence of a subsequent level functional PCBA, that level functional PCBA controls its control path switching unit to conduct the return path, causing the control signal to return to the coupler 4. The coupler 4 judges the closed-loop integrity of the control signal link based on whether the return control signal is received within a predetermined time window. When a feedback control signal is received, it indicates that the control path between the current functional PCBAs at each level is connected normally and the end module has formed a valid feedback. When no feedback control signal is received, it indicates that there is a connection abnormality, missing module, or switching abnormality in the link. Therefore, the system can automatically build and detect the integrity of the module link without manual configuration of the end module.

[0068] Second Embodiment like Figure 1 As shown, Figure 1 (a) is an exploded view of the main components of the system, including the bottom shell 11, the back plate 2, the screws fixing the back plate 2, the standard module 6, and the top shell 12. Figure 1(b) is a three-dimensional exploded view of the system, showing that the functional PCBAs are arranged in standardized mounting positions 8 and connected to the power supply bus and communication bus on the backplane 2 via board-to-board connectors 7. The upper shell 12 covers the entire modular structure, and the backplane 2 is fixed inside the bottom shell 11, with each module secured by screws. This exploded view clearly shows the spatial relationship and installation sequence between the shell 1, backplane 2, functional PCBAs, coupler 4 modules, and various connecting and fastening structures. Specifically, this application provides a customized integrated I / O system, including a shell 1, backplane 2, main control unit, coupler 4, external interface components 5, and multiple functional printed circuit board (PCBA) assemblies. These functional PCBAs can also be called standard modules 6. Standard modules 6 are functional printed circuit board assemblies formed according to uniform mechanical dimensions and basic electrical interface definitions. The backplane 2 is fixedly installed inside the shell 1, and the backplane 2 is provided with a power supply bus, a communication bus, multiple standardized mounting positions 8, and board-to-board connectors 7 corresponding to each standardized mounting position 8. Multiple functional PCBAs are installed in their corresponding standardized mounting positions 8 and electrically connected to the backplane 2 via board-to-board connectors 7 to access the power supply bus and communication bus. Each functional PCBA is arranged parallel to the backplane 2 and secured to it with screws, studs, or other fasteners 3, thus forming a compact, replaceable, modular assembly structure within the housing 1. External interface components 5 are located on the outside of the housing 1 and electrically connected to each functional PCBA to bring out the input and output signals of each functional PCBA.

[0069] Each standardized mounting position 8 adopts a unified mechanical mounting size and a unified basic electrical interface definition. The basic electrical interface definition includes at least a power supply interface and a communication interface, and preferably also includes an identification interface and a control interface. Therefore, different types of functional PCBAs can be mounted in any standardized mounting position 8. While maintaining the external dimensions of the housing 1, by replacing different types of functional PCBAs and / or configuring the functions of the functional PCBAs, one or more combinations of digital inputs, digital outputs, analog inputs, and analog outputs can be achieved. This structure gives the system a high degree of platformization, which helps reduce model differences, decrease the number of module models, and improve the convenience of production, maintenance, and field replacement.

[0070] To achieve adaptive management of functional PCBAs with varying assembly quantities, this application includes an independent control signal link in addition to the power supply bus and communication bus. This control signal link does not rely on the communication bus for enumeration, addressing, or end-point configuration; instead, it automatically forms the corresponding control topology using the physical connections between the functional PCBAs. Coupler 4, connected to the main control unit, serves as the starting and receiving end of the control signal link, sending control signals to each functional PCBA and receiving return control signals from the end functional PCBAs. The main control unit interacts with each functional PCBA via the communication bus for business data exchange, parameter configuration, and function management; the control signal link is primarily used to identify the connection sequence of functional PCBAs, determine the end-point position, and detect the integrity of the link loop. By separating business communication from topology control, system coupling is reduced, ensuring that even with a large amount of business data or significant changes in bus load, the formation and detection of the control topology remain relatively independent and stable.

[0071] Each functional PCBA is equipped with a module control unit, functional circuits, input / output connectors, and a control path switching unit. The module control unit interacts with the main control unit via the communication bus on the backplane 2, and simultaneously receives, processes, or transmits control signals in the control signal chain. The control path switching unit includes at least a first path and a second path, where the first path connects to the next-level functional PCBA, and the second path connects to the return path of the coupler 4. Thus, after a control signal reaches the current functional PCBA, it does not necessarily continue to be transmitted downwards. Instead, depending on whether the current functional PCBA is connected to a subsequent functional PCBA, it is either output to the next-level functional PCBA via the first path or returned to the coupler 4 via the second path, thereby forming a closed-loop control path.

[0072] like Figure 2 As shown, Figure 2 (a) is a schematic diagram of the backplane 2, showing multiple board-to-board connectors 7, mounting holes and standardized mounting positions 8 corresponding to each functional PCBA on the backplane 2; Figure 2 (b) is a schematic diagram of the structure after the coupler 4 module is assembled on the back plate 2, showing the installation position relationship between the coupler 4 module and the back plate 2; Figure 2(c) is a schematic diagram of the structure after multiple functional PCBAs are assembled on the backplane 2, showing that the functional PCBAs are arranged sequentially at intervals along the same side of the backplane 2 and mounted on the backplane 2 through corresponding standardized mounting positions 8. Specifically, in this embodiment, the backplane 2 is provided with a coupler 4 mounting area and multiple standardized mounting positions 8. The coupler 4 is mounted in the coupler 4 mounting area and is used to cooperate with the main control unit to realize the transmission, feedback and reception of control signals and link status detection. Multiple functional PCBAs are respectively assembled in their corresponding standardized mounting positions 8 to realize I / O functions such as digital input, digital output, analog input or analog output. Thus, the coupler 4 and the functional PCBAs structurally undertake the roles of system management and specific I / O function implementation, and they can be installed in different areas on the backplane 2.

[0073] Figure 3 This is a schematic diagram of the appearance of a customized integrated I / O system in an embodiment of the present invention, wherein, Figure 3 (a) shows the appearance of the customized integrated IO system from a first-view perspective. It can be seen that multiple external interface components 5 are provided on the outside of the housing 1. The external interface components 5 are used to bring out the input and output signals of each functional PCBA. Figure 3 (b) shows the appearance of the customized integrated IO system from a second perspective, showing the thickness of the housing 1 and the arrangement of some external interface components 5 relative to the side of the housing 1. Figure 3 (c) shows the appearance of the customized integrated IO system from a third-person perspective, showing the fixing structure and mounting holes on the bottom or back side of the housing 1.

[0074] Figure 4 This is a schematic diagram of the control topology of the customized integrated I / O system for this application. (See diagram for example.) Figure 4 As shown, the customized integrated I / O system includes coupler 4 and multiple sub-modules. Figure 4The submodules in this application can correspond to the functional PCBA, or they can also be called standard modules. Each submodule is sequentially connected to the control signal link according to its assembly order on the backplane 2. Coupler 4 includes a coupler master controller, which sends control signals to the first-level submodule and receives control signals returned by the last-level submodule via the feedback path. Each submodule contains a submodule master controller, input / output connectors, functional circuit units, and a control path switching structure. The functional circuit units are connected to the input / output connectors and are used to implement digital input, digital output, analog input, or analog output. The submodule master controller receives control signals and generates switch control signals based on the connection status of the subsequent submodules. The control path switching structure includes a switch controlled by the switch control signal, which is used to switch between the first and second paths. When the current submodule detects the existence of a next submodule or receives a connection confirmation signal from the next submodule, the current submodule master controller generates a switch control signal to activate the first path, switching the switch to the downstream state and transmitting the control signal to the next submodule. When the current submodule does not detect the existence of a subsequent submodule, or does not receive a connection confirmation signal from the next submodule, the switch remains in its default state or switches to the feedback state, allowing the control signal to be conducted through the feedback path and returned to coupler 4. Thus, the control signal is output from coupler 4 to the first-level submodule, and then transmitted sequentially through each submodule according to the assembly order. When it reaches the last submodule, since there is no next submodule in the last submodule, the switch in the last submodule remains in the default feedback state, allowing the control signal to return to coupler 4 through the feedback path. Through this structure, the system can automatically determine the last submodule based on the actual number of connected submodules, completing the adaptive closed-loop control signal link without manual setting of the last module or manual switching of the terminal state.

[0075] Figure 5 This is a diagram illustrating the closed-loop control mechanism of this application based on automatic switching of downstream connection states. Figure 5As shown in the diagram, this illustrates the path through which the coupler master controller sends control signals to multiple submodules (submodules N-1 to N), and the switch control units within each submodule. Specifically, the coupler master controller sends control signals to the first-level submodule master controller via its control signal output terminal. Each submodule includes a submodule master controller and a switch control unit. The switch control unit selectively transmits the control signal to the next submodule based on its presence or absence, or returns it to coupler 4 along the default feedback path. When the presence of the next submodule is detected and a valid control signal is received, the switch is activated to the next submodule, enabling signal transmission. When the next submodule is absent or the control signal is abnormal, the switch is activated to the feedback path, returning the control signal to coupler 4, forming a closed-loop control. With this structure, the system can automatically form a ring topology control path based on the actual number of connected submodules, without requiring manual setting of module ends or adjustment of switch states. It also enables automatic detection and confirmation of the end module position and link integrity. This configuration supports sequential cascading of N submodules and maintains the continuity and feedback capability of the control link even in default or abnormal module states.

[0076] Specifically, each functional PCBA is also equipped with a downstream presence detection unit to detect whether a downstream functional PCBA exists. This downstream presence detection unit is located at the connection interface between adjacent functional PCBAs and is electrically connected to the control path switching unit to output a switching control signal based on the detection result. When the current functional PCBA detects the existence of a downstream functional PCBA, the control path switching unit activates the first path, allowing the control signal to continue being transmitted to the next functional PCBA. When the current functional PCBA does not detect the existence of a downstream functional PCBA, the control path switching unit activates the second path, allowing the current functional PCBA to act as the link terminus and return the control signal to coupler 4. Thus, the control signal can sequentially pass from coupler 4 through the first functional PCBA, the second functional PCBA, and up to the Nth functional PCBA. When there is no downstream functional PCBA after the Nth functional PCBA, the Nth functional PCBA automatically assumes the end-of-line return function, sending the control signal back to coupler 4 to complete the closed loop.

[0077] The working principle of the above structure is that the system topology is not determined by software-preset module numbers, address DIP switches, master-slave configurations, or power-on enumeration, but rather by the actual physical connection state of each functional PCBA, which directly determines the flow of control signals. As long as a downstream functional PCBA exists, the control path switching unit activates the cascading path, extending the control signal downstream; if no downstream functional PCBA exists, the control path switching unit activates the feedback path, sending the control signal back to coupler 4, automatically forming a complete closed loop. This method achieves end-point identification, link closure, and module number adaptation in a multi-module system through hardware connections, which helps improve the determinism of system startup and reduces topology identification anomalies caused by software enumeration failures, address conflicts, or configuration errors.

[0078] The presence detection unit can be implemented in several ways, including (1) setting a dedicated detection pin in the connector between adjacent functional PCBAs. The current functional PCBA determines whether the subsequent functional PCBA is connected by applying a detection level to the detection pin and collecting the return level. When the subsequent functional PCBA exists, the detection pin forms a predetermined level state through the preset conduction structure inside the subsequent functional PCBA; when the subsequent functional PCBA does not exist, the detection pin is floating or maintains another predetermined level state. (2) a short-circuit identification circuit method can be used, that is, a short-circuit circuit or identification circuit is set at the input interface of the subsequent functional PCBA. The current functional PCBA determines whether the subsequent functional PCBA exists by detecting whether the circuit is conducting. (3) a resistance value identification network method can be used, that is, a predetermined resistance value network is set at the identification end of the subsequent functional PCBA. The current functional PCBA determines whether the subsequent functional PCBA is connected by detecting the voltage, current or voltage divider value of the identification end. In addition to determining whether the subsequent stage exists, this method can also be extended to identify the type of the subsequent module or the interface status. (4) A level detection method can be adopted, that is, a pull-up resistor or a pull-down resistor is set on the detection node. When the subsequent functional PCBA is connected, the state of the detection node is changed by its internal grounding, power supply or level holding circuit. The current functional PCBA determines whether the subsequent stage exists based on the detected high or low level. (5) A timing contact detection method can be adopted, that is, a detection terminal is set in the connector to make contact first or disconnect later, so that the detection terminal acts before the main signal terminal or disconnects after the main signal terminal during the module insertion or removal process, so that the system can sense the connection status of the subsequent module first, which is particularly suitable for scenarios that need to support hot-swapping or online maintenance.

[0079] To improve detection stability, the subsequent presence detection unit can also be equipped with filtering circuits, debouncing circuits, and delay confirmation circuits. Only when the detection status continuously meets a predetermined time condition or a predetermined number of times is the presence or absence of the subsequent functional PCBA determined, and the corresponding switching control signal is output. This design avoids misjudgments caused by connector insertion jitter, momentary poor contact, or external interference, reduces the risk of repeated switching by the control path switching unit, and thus improves the system's robustness in industrial environments.

[0080] The control path switching unit can be implemented using analog switches, relay switches, digital multiplexers, tri-state buffers, transistor conduction networks, or other equivalent switching devices. For applications with a relatively simple level range, high switching speed requirements, and limited power consumption, analog switches are preferred; for industrial scenarios with high isolation requirements, strong anti-interference requirements, or complex operating environments, relays are preferred; for scenarios requiring close integration with digital logic control, digital multiplexers or tri-state buffers are preferred. Those skilled in the art can select the appropriate device based on the control signal type, response time, isolation level, anti-interference requirements, and cost factors.

[0081] Preferably, the default state of the control path switching unit is set to the second path conduction state, that is, the return path is the default conduction path. In other words, when no downstream functional PCBA is detected, the detection result is abnormal, the module is in the power-on initialization stage, the switching control signal is missing, or the module fails to power down, the control signal defaults to returning to coupler 4 via the second path. Only when the downstream functional PCBA is detected to be effectively connected, and the corresponding switching control signal meets the predetermined stability conditions, will the control path switching unit switch to the first path conduction state. This default return design can avoid the control signal being suspended at the end of the link, reduce the risk of false transmission, false triggering, and uncertain end state, and enable the system to maintain better predictability and fault safety during startup, fault conditions, and plugging / unplugging. If necessary, the control path switching unit can also be set with a latching function to maintain the current conduction state before the detection result stabilizes, in order to further suppress frequency switching.

[0082] Coupler 4 or the main control unit can perform closed-loop integrity detection on the control signal link based on the feedback control signal received by coupler 4. Specifically, after coupler 4 sends a control signal to the first-level functional PCBA, the control signal is transmitted sequentially through each level of functional PCBA. When a certain level of functional PCBA does not detect the existence of a subsequent level of functional PCBA, that level of functional PCBA conducts the control signal to the feedback path through its control path switching unit and returns it to coupler 4. Coupler 4 or the main control unit determines whether the current control signal link is closed and complete based on whether the corresponding feedback control signal is received within a predetermined time window. When a feedback control signal is received within the predetermined time window, it can be determined that the current link is connected normally and the end has been effectively formed; when no feedback control signal is received within the predetermined time window, it can be determined that there is a connection abnormality, module missing, switching abnormality, or feedback abnormality in the link. Thus, the closed loop not only constitutes the transmission path of the control signal, but also constitutes the system's self-test path, which is beneficial for realizing module assembly status confirmation, end position confirmation, and link connectivity status diagnosis.

[0083] In further implementations, coupler 4 or the main control unit can infer the location of the terminal functional PCBA, the number of connected functional PCBAs, the link length, or abnormal segments based on one or more parameters, including the presence status, reception time, level status, pulse width, delay characteristics, or coding characteristics of the returned control signal. If necessary, each functional PCBA can also superimpose a predetermined delay, characteristic pulse, or coding identifier onto the control signal passing through this module to enhance fault location and online diagnostic capabilities. In this way, without interrupting service data communication, the system can utilize an independent control signal link for periodic online inspections, thereby improving operational reliability.

[0084] In addition to a unified control link interface, each functional PCBA can also be equipped with an identification circuit or storage unit to store the type information of the corresponding functional PCBA. The pins of the board-to-board connector 7 can include at least a power pin group, a ground pin group, a communication pin group, and an identification pin group. The main control unit reads the type information of the corresponding functional PCBA through the identification pin group and establishes the corresponding channel function mapping relationship accordingly. In this way, the system can not only achieve free assembly of any standardized mounting position 8 in terms of mechanical structure, but also logically identify the functional type of the installed modules, thus providing a foundation for subsequent parameter configuration, channel definition, and function allocation.

[0085] At least one functional PCBA may also be equipped with a channel configuration circuit. The channel configuration circuit may include one or more of hardware jumper units, DIP switches, analog switches, and relays, used to configure the functions of at least some channels on the functional PCBA. After reading the configuration parameters corresponding to the channel configuration circuit, the main control unit can control the corresponding channel to perform digital input, digital output, analog input, or analog output. In this way, while maintaining the overall form factor and installation structure, the system can further improve its customization capabilities by combining functional PCBA type replacement with channel-level configuration.

[0086] Figure 1 In (b) of the diagram, a backplate 2 is provided inside the housing 1. The backplate 2 has multiple standardized mounting positions 8. Each functional PCBA is connected to the backplate 2 through a corresponding board-to-board connector 7, and the backplate 2 provides the power supply bus and communication bus. The coupler 4 is connected to the main control unit, and the external interface component 5 is located on the outside of the housing 1 to bring out the input and output signals of each functional PCBA. Figure 1 This mainly reflects the platform-based structural features of the IO system in this application, that is, under a fixed housing size 1, different IO function schemes are formed by combining and configuring different functional PCBAs.

[0087] Figure 4 A schematic diagram of the control topology of the customized integrated IO system of this application is shown. Figure 4 In this configuration, coupler 4 serves as both the transmitter and receiver of control signals, with multiple functional PCBAs sequentially connected to the control signal link. Each functional PCBA contains a module control unit, a downstream presence detection unit, and a control path switching unit. When a downstream functional PCBA exists, the control path switching unit connects to the output path of that downstream functional PCBA; when no downstream functional PCBA exists, the control path switching unit connects to the feedback path, allowing the current functional PCBA to act as the end module and send control signals back to coupler 4. Figure 5 This application mainly embodies the closed-loop control mechanism based on the automatic switching of the subsequent connection state, that is, the control link can be automatically reconfigured as the number of modules assembled changes, and finally form a closed loop.

[0088] Compared to traditional solutions that rely on software enumeration, address configuration, or manual end-point settings, this application enables automatic reconfiguration of control signal links based on physical connections by setting a unified back-end presence detection structure and control path switching structure in each functional PCBA. This eliminates the need for preset module addresses, differentiation between primary, relay, and end-point modules, and manual switching of terminal states, thus completing control link construction, end-point identification, and link integrity detection. This solution improves system standardization, assembly consistency, and field deployment efficiency, while reducing debugging and maintenance costs caused by improper configuration. Furthermore, by setting the return path as the default path, the system maintains a clear link endpoint and stable return logic during startup, anomalies, or plugging / unplugging, enhancing overall reliability and engineering feasibility.

[0089] In summary, the core innovation of this solution lies not in stringing together multiple modules, but in using a near-pure hardware approach to automatically handle three tasks that typically require software intervention: module quantity adaptation, link direction determination, and end-loop feedback. Traditional modular systems often require address switching, bus enumeration, master-slave configuration, or firmware parameter settings when expanding; otherwise, the master controller cannot know how many sub-modules are currently connected or which module is at the end. This solution, however, by setting up a unified master control unit, control signal channel, and automatic switching switch within each sub-module, allows the control link to be automatically reconfigured according to the physical connection relationship. As long as a module is connected, the link extends; once there is no next-level module, the current module immediately sends the control signal back to coupler 4, automatically forming a complete closed loop. In other words, the system topology is not identified by software, but naturally generated by the hardware connection relationship—this is its most fundamental innovation.

[0090] From an engineering implementation perspective, this solution can be divided into three implementation levels: The first layer is the structural layer. The system consists of a coupler 4 and multiple standardized submodules. The number of submodules can vary from 1 to 8. Each submodule includes input / output connectors, functional modules, an internal bus, a submodule master controller, and a control path switching unit. Coupler 4 serves as the control start point and closed-loop receiving point of the entire system, responsible for sending control signals, managing system status, and receiving the final returned link closure signal.

[0091] The second layer is the link layer. Control signals are transmitted between modules along fixed physical paths. Each submodule provides two possible output destinations: one to the next submodule and the other back to coupler 4. The switching switches inside the module automatically determine the destination based on whether the next module exists.

[0092] The third layer is the detection layer. To determine the presence of downstream modules, detection pins, short-circuit identification pins, resistance identification networks, or connector structures with sequential contact timing can be added to the module connector. The current module only needs to detect this identification signal to control the state of analog switches, relays, or digital multiplexers, thereby determining whether the control signal continues to be transmitted or returns in a closed loop.

[0093] A key advantage of this engineering solution is that all submodules can be made using identical hardware templates, eliminating the need to distinguish between module 1, end modules, or relay modules. During production, only one PCB, one set of connection rules, and one set of main control logic are required to accommodate the entire configuration range of modules 1 through 8. This directly reduces BOM management complexity, manufacturing costs, and maintenance costs. For field applications, installers do not need to worry about module addresses or system numbers; they only need to plug them in sequentially, and the system will automatically form an effective control link, significantly lowering the barrier to engineering implementation.

[0094] In terms of reliability, this approach offers greater engineering value than traditional simple cascade structures. A common problem with ordinary cascade structures is unclear end-point processing. If the end point is undefined, control signals may be suspended, reflected, or lost, making it impossible for the master controller to determine system integrity. However, through the design of the default backcoupler 4, the behavior of the last module is clearly defined. As long as no subsequent modules are detected, it automatically assumes the closed-loop responsibility. This allows the master controller not only to know that the control signal has traversed the entire topology, but also to perform link integrity checks, end-point confirmation, online module count estimation, and anomaly diagnosis. In other words, this closed loop is not only a connection method but also a natural self-checking mechanism.

[0095] From a functional perspective, the diagram also reflects the separation of control and functional paths. The control signal loop is primarily responsible for topology organization, link confirmation, and module sequence closure, while actual data interaction, business control, and power management are accomplished through the internal bus and functional modules. The advantage of this approach is clear responsibilities and no interference between them. Even with large volumes of business data and complex internal buses, the control topology itself remains simple and stable, making it particularly suitable for scenarios such as industrial control, distributed data acquisition, modular power supplies, intelligent instruments, and scalable actuators. For these scenarios, the biggest concern is the complexity of configuration and maintenance after expansion, a pain point addressed in this application.

[0096] It should be noted that the above embodiments are merely preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, various modifications and improvements can be made without departing from the concept of the present invention. For example, the communication bus may employ different communication protocols, the external interface component may employ other industry standard connectors, the identification circuit or storage unit may employ different implementation methods, and the number, layout, and channel configuration of the functional PCBAs may also be adjusted according to application requirements. All equivalent substitutions or transformations using the technical features described in this specification and claims should fall within the protection scope of this invention.

Claims

1. A customized integrated I / O system, characterized in that, Includes housing, backplane, multi-functional PCBA, main control unit, coupler and external interface components; The backplate is fixedly installed inside the housing. The backplate is provided with a power supply bus, a communication bus, multiple standardized mounting positions, and board-to-board connectors corresponding to each of the standardized mounting positions. Multiple functional PCBAs are respectively assembled in the corresponding standardized mounting positions and electrically connected to the backplane through the corresponding board-to-board connectors to access the power supply bus and the communication bus; Each of the aforementioned functional PCBAs is arranged in a direction parallel to the backplate and is independently fixed to the backplate by fasteners; The main control unit interacts with each of the functional PCBAs via the communication bus; The external interface component is located on the outside of the housing and is electrically connected to each of the functional PCBAs, for leading out the input and output signals of each of the functional PCBAs; With the housing dimensions fixed, the IO system can form one or more functions of digital input, digital output, analog input, and analog output by assembling different types of functional PCBAs on the standardized mounting positions and / or configuring the functional PCBAs. The IO system also includes a control signal link independent of the communication bus. The main control unit sends control signals to multiple functional PCBAs through the coupler. The coupler serves as the physical sender and receiver of the control signal link. Each of the functional PCBAs is connected to the control signal link in a predetermined order. Each functional PCBA is provided with a control path switching structure. The control path switching structure is used to return the control signal to the coupler along the feedback path when no next functional PCBA is detected after the current functional PCBA, thus forming a closed-loop control path.

2. The customized integrated I / O system according to claim 1, characterized in that, Both the power supply bus and the communication bus are located on the backplane, allowing any of the functional PCBAs to connect to the power supply bus and the communication bus via the corresponding board-to-board connector, obtain operating power from the power supply bus, and interact with the main control unit via the communication bus.

3. The customized integrated I / O system according to claim 2, characterized in that, Each of the standardized mounting positions has the same mechanical mounting dimensions and basic electrical interface definitions, which include at least a power supply interface and a communication interface, so that different types of the functional PCBAs can be assembled in any of the standardized mounting positions.

4. The customized integrated I / O system according to claim 3, characterized in that, Each board-to-board connector has at least a power pin group, a ground pin group, a communication pin group, and an identification pin group. The power pin group serves as the pin of the power supply interface and is electrically connected to the power supply bus to provide operating power to the corresponding functional PCBA. The ground pin group is electrically connected to the ground network on the backplane to provide grounding to the functional PCBA. The communication pin group serves as the pin of the communication interface and is electrically connected to the communication bus to complete data interaction between the corresponding functional PCBA and the main control unit. The identification pin group is used to transmit identification information for the corresponding functional PCBA type.

5. The customized integrated I / O system according to claim 4, characterized in that... Each of the functional PCBAs is provided with an identification circuit or storage unit for storing the type information of the corresponding functional PCBA. The main control unit reads the type information of the functional PCBA through the identification pin group and establishes a corresponding channel function mapping relationship based on the type information. The channel function mapping relationship is the correspondence between the standardized mounting position, the functional PCBA type, the channel number of the functional PCBA, and the input and output of the corresponding channel.

6. The customized integrated I / O system according to claim 5, characterized in that... Each of the functional PCBAs is provided with a module control unit and a control path switching unit. Each of the functional PCBAs is connected to the control signal link in sequence according to the assembly order on the backplane. The transmission path of the control signal link is a ring topology formed by outputting through the coupler, being transmitted sequentially through each of the functional PCBAs, and being transmitted back to the coupler through the end functional PCBA. The module control unit is used to receive the control signal and perform status control or status detection on the functional PCBA; The control path switching unit is controlled by a switch control signal and has a first path and a second path. The first path is used to output the control signal to the next function PCBA, and the second path is used to conduct the control signal to the feedback path to return to the coupler.

7. The customized integrated I / O system according to claim 6, characterized in that, Each of the aforementioned functional PCBAs is provided with a connection detection unit for detecting whether the next functional PCBA exists in the subsequent stage of the current functional PCBA. The connection detection unit is electrically connected to the control path switching unit. The connection detection unit generates a detection result based on the connection status of the next functional PCBA. The module control unit generates a switch control signal based on the detection result and controls the control path switching unit to activate either the first path or the second path via the switch control signal. When the connection detection unit detects the existence of the next functional PCBA, the module control unit generates a first switch control signal to enable the control path switching unit to conduct the first path so that the control signal is transmitted to the next functional PCBA; When the connection detection unit does not detect the existence of the next function PCBA, the module control unit generates a second switch control signal, or the control path switching unit remains in the default state, so that the control path switching unit turns on the second path, so that the control signal returns to the coupler via the feedback path.

8. The customized integrated I / O system according to claim 7, characterized in that, The connection detection unit includes one or more of the following: a detection pin, a short-circuit identification circuit, a resistance identification network, or a level detection circuit, which are disposed between adjacent functional PCBAs.

9. The customized integrated I / O system according to claim 7, characterized in that, The second path is the default conducting path, and the control path switching unit defaults to conducting the second path after power-on; When the connection detection unit does not detect the existence of the next functional PCBA, the detection result is abnormal, or the current functional PCBA is in the power-on initialization state, the module control unit generates a second switch control signal, or the control path switching unit maintains the default state, the control path switching unit maintains or switches to the second path, and makes the current functional PCBA, as the end functional PCBA, send the control signal back to the coupler; When the connection detection unit detects the existence of the next functional PCBA and the module control unit generates a valid first switch control signal, the control path switching unit switches from the second path to the first path so that the control signal is transmitted to the next functional PCBA.

10. The customized integrated I / O system according to claim 7, characterized in that, The control path switching unit includes one of an analog switch, a relay switch, a digital multiplexer, or a transistor conduction network, and is used to connect the first path or the second path according to the detection result of the connection detection unit or the control signal of the module control unit.

11. The customized integrated I / O system according to claim 9, characterized in that, The coupler or the main control unit is equipped with a closed-loop integrity detection unit, which is used to monitor the control signal returned to the coupler via the feedback path, and to determine the closed-loop integrity of the control signal link based on whether the control signal is received. Specifically, when the coupler receives the control signal within a preset time window, it is determined that the closed-loop of the control signal link is complete; otherwise, when the coupler does not receive the returned control signal or the signal is abnormal, it is determined that the control signal link is disconnected, has an abnormal contact, or has an abnormal switching.

12. The customized integrated I / O system according to claim 11, characterized in that, The closed-loop integrity detection unit is also used to acquire the return parameters of the control signal returned to the coupler. The return parameters include one or more of the following: return arrival time, return level status, return pulse width, and return encoding information. Based on the return parameters and preset judgment conditions, the unit determines the location of the end functional PCBA of the control signal link, the number of connected functional PCBAs, or the link connectivity status.

13. The customized integrated I / O system according to claim 1, characterized in that, Each of the functional PCBAs is arranged at intervals along the same side of the back plate. Each functional PCBA is fixed to the back plate by at least two fasteners located on both sides of the corresponding board-to-board connector. The housing and / or the back plate are provided with a limiting structure that cooperates with the edge of the functional PCBA. The limiting structure includes a stop, a limiting rib or a limiting step that abuts against the edge of the functional PCBA, and / or a positioning post that cooperates with the positioning hole on the functional PCBA, so as to limit the lateral displacement of the functional PCBA relative to the back plate.

14. The customized integrated I / O system according to claim 12, characterized in that, At least one of the aforementioned functional PCBAs is provided with a channel configuration circuit, the channel configuration circuit including at least one or more of hardware jumper units, DIP switches, analog switches, and relays; The hardware jumper unit or the DIP switch is used to generate the hardware configuration state corresponding to the channel, and the analog switch or the relay is used to switch the input and output signal paths corresponding to the channel. The main control unit is used to read the configuration parameters corresponding to the channel configuration circuit, and control the corresponding channel to perform the digital input, the digital output, the analog input or the analog output according to the configuration parameters. The configuration parameters include the channel function type determined by the hardware configuration state and / or the channel connection state determined by the input and output signal path.

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