REMOTE-I / O-SYSTEM

Description

[0001] The invention relates to a remote I / O system according to the preamble of claim 1.

[0002] A remote I / O system (remote input / output system) for use in a potentially explosive area includes a remote I / O module (remote input / output module). The remote I / O module is designed to securely connect sensors and actuators to a control system, such as a computer. The remote I / O module can be installed decentrally and transmit process data from binary and analog sensors and actuators from the potentially explosive area to the control system, for example, via a bus interface on the remote I / O module. Process data can also be transmitted from the control system to the potentially explosive area via the remote I / O module. Due to the reduced wiring effort provided by the remote I / O module, not only cables but also time, money, and labor can be saved.To prevent the remote I / O module from serving as an ignition source for an explosion, it is designed so that no sparks can occur despite the cables connected by the remote I / O module and the remote I / O module does not exceed a specified temperature value. To protect it from dust, especially flammable dust, and mechanical influences, the remote I / O module is arranged in a housing. The housing surrounds the remote I / O module on all sides, so that it is completely enclosed. The housing can also shield the remote I / O module from gases, especially flammable gases. Such housings enclose a large volume that is many times larger than the installation space of the remote I / O module. Consequently, the entire remote I / O system requires a large installation space. Typically, the housing is a control cabinet. The housing has a box and a cover.In order to open the cover and check the status of the remote I / O module using a display on the remote I / O module, it is first necessary to ensure that no flammable gases can penetrate the remote I / O module when opening the housing. To do this, the gas concentration in the ambient air must be determined in a so-called clearance measurement.

[0003] JP 2005-348542 A discloses a radio for use in potentially explosive atmospheres. Its base body has electrical contacts and is arranged in a housing. Cables are routed from the electrical contacts of the base body through a cover of the housing. The housing encloses a large installation volume.

[0004] The invention is based on the objective of further developing a generic remote I / O system in such a way that the remote I / O system requires a small installation space.

[0005] This task is solved by a remote I / O system with the features of claim 1.

[0006] The invention provides that the housing cover rests directly on the base body of the remote I / O module. This eliminates any gap between the remote I / O module and the cover. This allows the remote I / O system to be designed so that there is no free space between the cover and the remote I / O module. This saves installation space. The remote I / O system can be manufactured in a space- and material-saving manner.

[0007] The remote I / O system box is advantageously formed by the base body of the remote I / O module. The box and the base body are expediently formed integrally with each other. In particular, the box and the base body are made of the same material. This means that the remote I / O system box and the base body of the remote I / O module are the same component. This saves material and simplifies manufacturing. Furthermore, the remote I / O system is smaller. This makes the remote I / O system more compact and stable. The remote I / O module already includes the housing. No additional or separate protective housing is required. The remote I / O module can be installed directly in the potentially explosive area.

[0008] The housing should ideally have at least one opening for routing the electrical cable. This allows an electrical cable to be easily connected to the at least one terminal via the opening.

[0009] In particular, the feed-through opening is a cable gland for the tight insertion of cables from an outside to an inside of the housing. The cable gland's armored thread is advantageous. This allows cables to be inserted into the interior of the housing while maintaining a tight seal on the outside.

[0010] The integrated cable entry in the base body is advantageous. This allows a cable routed through the entry to be easily connected to at least one port. This enables the remote I / O system to be designed with a low profile.

[0011] In an alternative embodiment, the through-opening is formed in the cover. If a remote I / O module is defective, it is sufficient to simply replace the base body of the remote I / O module. The cable can remain routed through the cover, and the cover can be placed on a new base body together with the cable. This saves time and material. Advantageously, the at least one connection has a clamp or snap-in connection. This can be released when the base body is replaced. This allows the connection of the at least one cable to the base body of the remote I / O module to be easily released and closed again. Expediently, several cables can be connected to the base body simultaneously using a clamp or snap-in connection.

[0012] It may also be provided that several through-openings are provided. In particular, one of the several through-openings is provided in the cover and one in the base body.

[0013] According to the invention, the base body has a receiving space for the connection. Advantageously, the receiving space is bounded by a wall that runs continuously around an axis. This axis extends, in particular, from the bottom of the receiving space to an opening of the receiving space. This ensures that the connection is protected within the receiving space. A cover can easily conceal the receiving space.

[0014] The remote I / O system conveniently features an outer wall facing the environment, which simultaneously serves as the outer wall of the enclosure and the base unit. Advantageously, this outer wall is part of the receiving chamber wall. This allows the remote I / O system to be designed, for example, so that the feed-through opening leads directly into the receiving chamber wall. This simplifies connecting the cable to the at least one port.

[0015] In particular, the receiving space has an opening. The opening is conveniently closed by the cover. Advantageously, the opening is tightly sealed by the cover to prevent the passage of gases, especially flammable gases. This reliably prevents gases from penetrating the connections.

[0016] In an advantageous embodiment of the invention, the remote I / O module has a display integrated into the base body and not obscured by the cover. This allows the connections to remain protected by the cover, while simultaneously enabling the status of the remote I / O module to be checked visually. Opening the housing is not required for this purpose. Advantageously, the display is an LED indicator.

[0017] At least one electrical circuit is advantageously arranged in the base body of the remote I / O module. The electrical circuit is, in particular, a printed circuit board. Advantageously, the electrical circuit is encapsulated in the base body using an electrically insulating material. The electrically insulating material is advantageously a synthetic resin.

[0018] In particular, the base body is made at least partially of aluminum. The lid is preferably made at least partially of aluminum.

[0019] An embodiment of the invention is explained below with reference to the drawings. They show: Fig. 1 and 2perspective views of a remote I / O system, Fig. 3 and 4side views of the remote I / O system from the Figures 1 and 2 , Fig. 5 a schematic representation of a section along the section plane VV from Fig. 4 , Fig. 6 a perspective view of a cover of the remote I / O system from the Figures 1 and 2, Fig. 7 a schematic representation of a section along the section plane VII-VII from Fig. 3 and Fig. 8 a side view of the remote I / O system from the Figures 1 and 2 .

[0020] Fig. 1 shows a remote I / O system 1. The remote I / O system 1 is also referred to as a remote input / output system. Another name for the remote I / O system 1 is a decentralized input / output system. The remote I / O system 1 includes a remote I / O module 2. Similarly, the remote I / O module 2 is also referred to as a remote input / output module or a decentralized input / output module.

[0021] The remote I / O module 2 has a bus interface (not shown). Electrical signals can be transmitted via the bus interface of the remote I / O module 2. Sensors and / or actuators can be connected to a control system (not shown) using the remote I / O module 2. The sensors and / or actuators can be digital or analog sensors and / or actuators. The control system is, for example, a control unit or a computer. In the exemplary embodiment, the control system is a programmable logic controller. Typically, process data from the sensor and / or actuator is transmitted to the control system via the remote I / O module 2, or process data is transmitted from the control system to the sensor and / or actuator via the remote I / O module 2.

[0022] The remote I / O module 2 is designed for use in an explosion-protected area. The explosion-protected area is also referred to as a potentially explosive zone. The remote I / O module 2 is designed so that it does not constitute an ignition source for an explosive substance. No sparks are generated during operation of the remote I / O module 2. The remote I / O module 2 is designed so that it does not exceed a specified limit temperature. The remote I / O module 2 is designed for use in zones 1 and 21 as defined in Directive 2014 / 34 / EU. The remote I / O system 1 is designed for use in zones 1 and 21 as defined in Directive 2014 / 34 / EU. Accordingly, the remote I / O module 2 is designed for an area in which an explosive atmosphere consisting of a mixture of air and flammable gases, vapors, or mists can occasionally form during normal operation.Furthermore, the Remote I / O Module 2 is designed for an area where, during normal operation, an explosive atmosphere in the form of a cloud of combustible dust in the air may occasionally form. The Remote I / O System 1 is also designed for these two areas.

[0023] This allows the remote I / O system 1 to be installed decentrally in a potentially explosive area. A sensor and / or actuator can be installed in the potentially explosive area, which is connected via the remote I / O system 1 to a control system located outside the potentially explosive area. This allows the sensor and / or actuator to be safely controlled and / or monitored from the control system. The bus interface of the remote I / O module 2 reduces wiring requirements.

[0024] The remote I / O module 2 comprises a base body 3. At least one connection 4 is arranged on the base body 3, as shown in Fig. 5 shown. A cable 5 can be connected to connection 4. The cable 5 connects the remote I / O module 2 to an actuator and / or a sensor (not shown). A control connection 18 is arranged on the base body 3. A control line 19 can be connected to the control connection 18. The control line 19 connects the remote I / O module 2 to the control system. The control line 19 has a connector (not shown) at its end facing the remote I / O module 2. The connector plugs the control line into the control connection 19.

[0025] The remote I / O system 1 comprises a housing 6 ( Figures 1 and 2). The housing 6 has a box 7 and a cover 8. The connector 4 is arranged in the housing 6. The housing 6 surrounds the connector 4 on all sides. The housing 6 completely encloses the connector 4. The connector 4 is arranged in the box 7. The housing 6 is sealed against gases, in particular against highly flammable gases.

[0026] The remote I / O system 1 is designed according to DIN EN 60529 with IP protection class IP67 (International Protection or Ingress Protection). Accordingly, the housing 6 is dustproof. The housing 6 provides complete protection against contact for the components located within the housing 6. The housing 6 provides protection against temporary submersion.

[0027] The cover 8 of the housing 6 lies directly against the base body 2 of the remote I / O module 2. There is no gap between the base body 2 and the cover 8. The cover 8 lies flat against the base body 3. The base body 2 has a receiving space 12 for the connection 4 ( Fig. 5 ). The cover 8 completely covers the receiving space 12 for the connector 4. The cover 8 seals the receiving space 12 tightly against gases. The receiving space 12 provides space for the end of the cable 5, which is guided through the through-opening 9. The individual wires of the cable 5 are connected to the connector 4 in the receiving space 12.

[0028] The box 7 of the housing 6 of the remote I / O system 1 is formed by the base body 3 of the remote I / O module 2. The box 7 and the base body 3 are formed as a single piece. The box 7 and the base body 3 are the same component. The box 7 and the base body 3 are made of the same material. The base body 3 is made of aluminum. The surface of the base body 3 is formed by a protective layer. The protective layer protects against corrosion and mechanical damage to the base body 3. In the exemplary embodiment, the protective layer is an electrochemically deposited metal layer. The protective layer is applied by electroplating. However, it can also be provided that the protective layer is produced by anodizing the aluminum. Alternatively or additionally, the base body 3 can also be made at least partially of zinc. It can be provided that the base body is produced using a zinc die-casting process.As a further possibility, the base body 3 can be made at least partially of plastic. Advantageously, the base body 3 is then manufactured using an injection molding process. Even with alternative materials for the base body 3, a protective surface layer can be provided on the surface of the base body 3. One possibility for applying such a protective layer is also available for base bodies made of zinc by electroplating.

[0029] As in Fig. 5As shown, the receiving space 12 is delimited by a receiving space wall 13. The receiving space 12 has a base 20. The base 20 is delimited by the receiving space wall 13. The receiving space 12 has an opening 15. The opening 15 is opposite the base 20. The receiving space wall 13 extends between the opening 15 and the base 20. An axis 50 runs through the receiving space 13. The axis 50 runs along an opening direction 49. The opening direction 49 points from the base 20 to the opening 15. The axis 50 pierces the base 20. The axis 50 is spaced from the receiving space wall 13. The receiving space wall 13 encloses the axis 50. The receiving space wall 13 runs closed around the axis 50. When the housing 6 is closed, the opening 15 is closed by the cover 8. In order to protect the housing 6 ( Fig. 1 ), the cover 8 ( Fig. 6 ) in opening direction 49 from the base body 3 ( Fig. 5 ) removed.

[0030] The remote I / O system 1 has an outer wall 14. The outer wall 14 delimits the remote I / O system 1 with respect to the outer side 10 of the remote I / O system 1 ( Fig. 5 ). The outer wall 14 is the outer wall of the box 7. The outer wall 14 is the outer wall of the base body 3. The box 7 and the base body 3 have a common outer wall 14. A part of the outer wall 14 is part of the receiving space wall 13 of the receiving space 14.

[0031] As in Fig. 5As shown, the housing 6 has a feed-through opening 9 for the passage of the electrical conductor 5. The conductor 5 is guided through the feed-through opening 9 from the outside 10 to the inside 11 of the housing 6. In this embodiment, the feed-through opening 9 is a cable gland. The cable gland allows for a tight seal of the conductor 5 from the outside 10 to the inside 11. The cable gland seals the housing 6 against gases. In this embodiment, the cable gland has a reinforced thread.

[0032] In the exemplary embodiment, both in the base body 3 ( Fig. 5 ) as well as in the lid 8 ( Fig. 6) a through-opening 9 is arranged. However, it can also be provided that a through-opening is arranged only in the cover 8. The base body 3 is then free of through-openings. Likewise, it can be provided that a through-opening is arranged only in the base body 3. The cover 8 is then free of through-openings.

[0033] The cable 5 is guided through the through-hole 9 and connected to the connection 4 ( Fig. 5In the exemplary embodiment, terminal 4 is a clamp. The clamp can accommodate wires in several receptacles. For this purpose, each receptacle has a receiving opening 26. In the exemplary embodiment, terminal 4 is detachably connected to the base body 3. This allows the conductor 5 to be conveniently connected to terminal 4 when terminal 4 is detached. Terminal 4 is then reconnected to the base body 3. The clamp is connected to the base body 3 of the remote I / O module 2 via a clamping connection. However, it is also possible for the clamp to be connected to the base body 3 via a snap-fit ​​connection. The clamp has an electrical contact at its end facing away from the receiving openings 26 (not shown). When the clamp is inserted, the electrical contact makes contact with an electrical circuit 17 ( Fig. 7) of the remote I / O module 2. Several electrical contacts are provided in an analog manner. The combination of the terminal receptacles and the electrical contacts creates the digital inputs and outputs of the remote I / O module 2. The digital inputs are designed according to the NAMUR standard. The digital outputs are designed for a voltage of 24 V. Analog sensors and / or actuators can be connected to the remote EO module 2 via a current loop interface. The loop current can range from 4 mA to 20 mA.

[0034] As shown in the sectional view in Fig. 7As shown, a compartment 21 is formed inside the base body 3. The compartment 21 serves to hold the electrical circuit 17. The electrical circuit 17 is a circuit board. The electrical circuit 17 is embedded in an electrically insulating material. The electrically insulating material is synthetic resin. The electrical circuit 17 is cast into the base body 3 by means of the electrically insulating material. For this purpose, the compartment 21 is filled with the electrically insulating material. The terminal connects the conductor 5 to the electrical circuit 17.

[0035] As in Fig. 5As shown, the base body has a second receiving space 22. The second receiving space 22 serves to receive the control connection 18. The second receiving space 22 is covered by a cover 8, similar to the receiving space 12. The control connection 18 connects the control line 19 to the electrical circuit 17. The control line 19 is guided through a second feedthrough 23 from the inside 11 to the outside 10. The second feedthrough 23 is designed similarly to the feedthrough 9. It can also be installed in the cover 8 ( Fig. 6 ) as well as in the base body 3 ( Fig. 5 It can be provided for either only in the lid or only in the main body.

[0036] The Fig. 6The cover 8 shown is made of aluminum. The surface of the cover 8 is formed by a protective layer. This protective layer protects against corrosion and mechanical damage to the cover 8. In the exemplary embodiment, the protective layer is an electrochemically deposited metal layer. The protective layer is applied by electroplating. However, it can also be provided that the protective layer is produced by anodizing the aluminum.

[0037] It may be provided that in the Fig. 5In the illustrated base body 3, a recess is arranged for receiving a projection of the cover 8. The recess extends in the direction opposite to the opening direction 49. Advantageously, the recess runs in a closed manner around the axis 50. In particular, the recess is arranged in an end face 24 of the receiving space wall 13. The receiving space wall 13 runs in a closed manner around the axis 50. When arranged on the receiving space 13, the projection of the cover 8 expediently runs in a closed manner around the axis 50. Advantageously, the projection of the cover 8 is designed to correspond to the recess in the base body 3. The recess can also be referred to as a groove and the projection as a tongue. The interaction of the projection and recess enables simple positioning of the cover 8 on the base body 3. The interaction of the projection and recess ensures a tight connection between the cover 8 and the base body 3.It may also be provided that a seal is arranged between the projection and the recess. Alternatively, the projection may be provided on the base body 3 and the recess in the cover 8.

[0038] The cover 8 is fastened to the base body 3 by means of at least one fastening means (not shown). In the exemplary embodiment, the fastening means is formed by a screw, a hole in the cover 8, and a thread in the base body 3. In the exemplary embodiment, the cover 8 is fastened to the base body 3 with several screws.

[0039] In the exemplary embodiment, the opening 15 of the receiving space 12 is formed in a single plane. The receiving space 12 is open in the opening direction 49. However, it can also be provided that the receiving space 12 is open in more than one direction, so that multiple planes can be applied to the opening 15. The cover 8 is then designed to correspond to the geometry of the opening 15. For example, the shape of the cover 8 can be substantially L-shaped in cross section.

[0040] As in the Figures 3 and 5As shown, the remote EO module 2 has a display 16. The display 16 is an LED indicator. The display 16 is formed by LEDs. The LEDs may be arranged in the form of a light bar. The display 16 is attached to the inside 11 of the base body 3 and is visible from the outside 10 through corresponding display openings in the base body 3. The display 16 is located on the base body 3 of the remote I / O module 2. The display 16 is not obscured by the cover 8. The display 16 is visible from the outside 10 even when the housing 6 is closed.

[0041] As in Fig. 8 As shown, the base body 3 is closed at its bottom by a cover 25. The cover 25 is attached to the base body 3 by means of screws. The cover 25 can be removed from the base body 3 in the direction opposite to the opening direction 49. This allows access to the electrical circuit 17.

[0042] As a safety precaution, the remote I / O module 2 includes a current measuring device for measuring the current flowing through individual channels. The remote I / O module 2 also has a voltage measuring device for detecting overvoltages and / or undervoltages. The remote I / O module 2 includes a temperature sensor that measures the temperature of the remote I / O module 2.

[0043] Thanks to the multitude of measurements, errors can already be detected in the remote I / O module 2. In the simplest case, this could be a short circuit, a voltage outside the permissible voltage range, an excessively high temperature, or a pre-failure indication (predictive maintenance).

[0044] The control system can evaluate this measurement data. In the example, a control device is provided for this purpose. The control device is part of the remote I / O module 2.

[0045] If a temperature limit is exceeded, the remote I / O module 2 is switched off by the control device.

[0046] The controller of the remote I / O module 2 makes decisions based on learned processes. For this purpose, an AI algorithm representing artificial intelligence is stored in the controller.

[0047] The remote I / O module 2 can operate independently via the control device. The control device's AI algorithm allows the remote I / O module 2 to independently learn the system process.

[0048] The data supplied to the remote I / O module 2 by the connected sensors and / or actuators, as well as the measurement data from the remote I / O module 2, are collected and evaluated by the AI ​​algorithm over an extended period of time. An artificial neural network is implemented in the control device, which uses deep learning to identify structures in the collected data and make decisions based on these. In particular, any anomalies that occur can be reliably classified as critical or non-critical. This reduces the data transfer from the remote I / O module 2 to the control system. The data does not need to be continuously forwarded or queried; instead, it is pre-filtered by the control device.

[0049] It can also be planned for the control device to completely replace the control system. The control device then controls the remote I / O module 2 completely independently. The individual control steps are controlled by the AI ​​algorithm.

Claims

1. Remote I / O system for use in a zone where there is an explosion hazard, wherein the remote I / O system comprises a remote I / O module (2) with a main body (3), wherein at least one connection (4) for an electrical line (5) is arranged on the main body (3), wherein the remote I / O system (1) comprises a housing (6) with a box (7) and a cover (8), and wherein the connection (4) is surrounded on all sides by the housing (6), so that the connection is completely enclosed in the housing (6), characterized in that the main body (3) has a receiving space (12) for the connection (4), in that the cover (8) completely covers the receiving space (12), in that the cover (8) of the housing (6) lies directly on the main body (3) of the remote I / O module (2).

2. Remote I / O system according to Claim 1, characterized in that the box (7) of the remote I / O system (2) is formed by the main body (3) of the remote I / O module (2).

3. Remote I / O system according to Claim 1 or 2, characterized in that the box (7) and the main body (3) are formed integrally with one another.

4. Remote I / O system according to one of Claims 1 to 3, characterized in that the box (7) and the main body (3) are formed from one and the same material.

5. Remote I / O system according to one of Claims 1 to 4, characterized in that the housing (6) has at least one feedthrough-opening (9) for feeding through the electrical line (5).

6. Remote I / O system according to Claim 5, characterized in that the feedthrough opening (9) is a screwed cable gland for the sealed introduction of a line from an outer side (10) of the housing (6) to an inner side (11) of the housing (6).

7. Remote I / O system according to Claim 5 or 6, characterized in that the feedthrough opening (9) is formed in the main body (3).

8. Remote I / O system according to Claim 5 or 6, characterized in that the feedthrough opening (9) is formed in the cover (8).

9. Remote I / O system according to one of Claims 1 to 8, characterized in that the receiving space (12) is bounded by a receiving-space wall (13), and in that the receiving-space wall (13) runs continuously around an axis (50).

10. Remote I / O system according to one of Claims 1 to 9, characterized in that the remote I / O system (1) has an outer wall (14) towards the surroundings, and in that the outer wall (14) is at the same time the outer wall of the box (7) and of the main body (3).

11. Remote I / O system according to either of Claims 9 and 10, characterized in that the outer wall (14) is part of the receiving-space wall (13).

12. Remote I / O system according to one of Claims 9 to 11, characterized in that the receiving space (12) has an opening (15), and in that the opening (15) is closed by the cover (8).

13. Remote I / O system according to one of Claims 1 to 12, characterized in that the remote I / O module (2) has a display (16), in that the display (16) is formed on the main body (3), and in that the display (16) is not covered by the cover (8).

14. Remote I / O system according to one of Claims 1 to 13, characterized in that in the main body (3) of the remote I / O module (2) there is at least one electrical circuit (17).

15. Remote I / O system according to Claim 14, characterized in that the at least one electrical circuit (17) is encapsulated in the main body (3) by means of an electrically insulating material.