Input / output device and method for monitoring and / or controlling a dynamic environment

Abstract

To monitor and / or control a dynamic environment.SOLUTION: A device and method for performing adaptable input / output signal transmission over the same signal channel is described. A programmable interface circuit includes a signal channel capable of being designed to transmit and / or receive different kinds of analog and digital signals prior to use or during operation. The interface circuit may be used for communication between an isolated communication controller and any of components of a machine using diverse kinds of signal transmissions.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 62 / 931,188, filed November 5, 2019, entitled "Input / Output Methods and Apparatus for Monitoring and / or Controlling Dynamic Environments," which is incorporated herein by reference in its entirety.

[0002] A portion of a modern automated or semi-automated machine (e.g., in an industrial environment such as a factory assembly and / or inspection line) may include tens to hundreds of components, which may be controlled and / or monitored by one or more remote devices. For example, there may be disparate components (sensors, actuators, encoders, motors, power supplies, light sources, imagers, image processors, conveyors, controllers, signal processors, signal generators, etc.) to which data and / or control signals may be sent and / or received from the components.

[0003] Modern manufacturing machines used in various types of factories may have hundreds of such heterogeneous components available from many different vendors. A diverse ecosystem of different components allows designers of modern machines to assemble multiple components of machines that can satisfy an almost infinite set of design goals without having to invent a custom component for every unique application. Examples of machines that may be composed of multiple components include manufacturing machines, autonomous vehicles, modern automobiles, aircraft, wind turbines, and power plants.

[0004] Components for machines are frequently produced in larger quantities than are needed for any single end-user application, thereby reducing the fixed and variable costs associated with manufacturing the components. This business model is based on the expectation that large quantities of components will be sold to many end users and / or used in many different end-user applications. As a result of mass production, many components for machines are designed without regard to specific end-user applications. As such, such components are typically not optimized for a specific application. Lack of component optimization at the design stage means that a relatively large number of components may be used in an automated / semi-automated machine, but the full functionality or capabilities of the components may not be fully utilized. Furthermore, adapting the functionality of one or more included components to achieve specific design goals for the automated / semi-automated machine may require the addition of one or more matching components. In short, the generality of non-custom machine components can add significant complexity and cost to automated / semi-automated machines equipped with such components. Summary of the Invention

[0005] Described herein are apparatus and methods of the present invention related to programmable input / output interface circuits for automated / semi-automated machines. Examples of programmable interface circuits can be used, for example, to assist in controlling the dynamic environment of an automated / semi-automated machine and can be located between a controller and one or more components of the machine that are controlled and / or from which data can be received. Such components include sensors and actuators, such as, but not limited to, temperature sensors, light sensors, wind sensors, pressure sensors, speed sensors, proximity detectors, strain gauges, X-ray detectors, radiation sensors, chemical sensors, humidity sensors, flame detectors, smoke or dust sensors, light sources, light curtains, galvanometers, encoders, motors, power supplies, light sources, imaging devices, image processors, conveyors, controllers, signal processors, signal generators, robotic devices, and the like. According to some implementations, the programmable interface circuits of the present implementations can be programmed (either before use of the machine or in real time while the machine is operating) to interface with a wide variety of components that use different types of signaling (e.g., different types of digital / analog signaling). In some implementations, the interface circuitry can transmit and receive different types of signals over the same signal channel. The ability to transmit and receive different types of signals over the same signal channel can require fewer interconnect cables, reduce interconnect complexity, reduce the footprint of the controller, reduce implementation and operation costs, and provide more reliable operation.

[0006] Briefly, various implementations are directed to a programmable interface circuit capable of adaptively exchanging signals between an isolated communications controller and a machine component. In one implementation, the programmable interface circuit includes a plurality of interconnects for receiving a programming voltage from the isolated communications controller and signal channels for transmitting signals between the programmable interface circuit and the component. The programmable interface circuit also includes a programmable analog I / O circuit for connecting to the signal channels and receiving a first signal from the isolated communications controller, a programmable digital I / O circuit for connecting to the signal channels and receiving a second signal from the isolated communications controller, and a current detection circuit for detecting an amount of current flowing through the signal channels. The programmable interface circuit is programmable based on at least a first programming voltage when applied to the plurality of interconnects during operation to provide a first analog signal to the signal channels based on the first signal received from the isolated communications controller or to provide a first digital signal to the signal channels based on the second signal received from the isolated communications controller.

[0007] In one implementation, the programmable interface circuit includes a plurality of interconnects and signal channels for transmitting signals between the programmable interface circuit and the component. The programmable interface circuit also includes a programmable analog I / O circuit for connecting to the signal channels to receive a first signal from the isolated communications controller and a programmable digital I / O circuit for connecting to the signal channels to receive a second signal from the isolated communications controller. The programmable interface circuit is programmable based on at least a first programming voltage when the first programming voltage is applied to the plurality of interconnects during operation to provide a first analog signal to the signal channels based on the first signal received from the isolated communications controller or a first digital signal to the signal channels based on the second signal received from the isolated communications controller.

[0008] Some implementations are directed to methods of operating a programmable interface circuit. An example method of operating a programmable interface circuit can include receiving a first programming voltage from an isolated communications controller to program the interface circuit to receive a first signal for transmission to a component of a machine, where the first signal can be either an analog signal or a digital signal. The example method can further include receiving the first signal from the isolated communications controller and transmitting a first output signal to a signal channel of the programmable interface circuit based on the received first signal, where the first output signal is the same type of signal as the received first signal. The example method can also include receiving a second programming voltage to program the interface circuit to receive a second signal on the signal channel from the component, where the second signal is a different type of signal than the first signal, and transmitting a first input signal to the isolated communications controller based on the received second signal.

[0009] The foregoing and other aspects, implementations, and features of the present teachings may be better understood from the following description taken in conjunction with the accompanying drawings. It is understood that all combinations of the foregoing aspects, implementations, and features, and additional aspects, implementations, and features discussed in more detail below (provided such aspects, implementations, and features are not mutually inconsistent), are considered to be part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are considered to be part of the inventive subject matter disclosed herein. [Brief explanation of the drawings]

[0010] Those skilled in the art will understand that the drawings are primarily for illustrative purposes and are not intended to limit the scope of the inventive subject matter described herein. The drawings are not necessarily to scale, and various aspects of the inventive subject matter disclosed herein may in some cases be shown exaggerated or enlarged in the drawings to facilitate an understanding of various features. In the drawings, like reference characters generally refer to like features (e.g., functionally similar and / or structurally similar elements). [Figure 1] 1 illustrates an example of a portion of a conventional control architecture and apparatus for machine automation. [Figure 2A] 2 illustrates an example of a wiring harness that can be used with the conventional control architecture shown in FIG. 1. [Figure 2B] 2 illustrates an example of cabling within an instrument rack of the conventional control architecture shown in FIG. 1. [Figure 3] 4 illustrates an example of a portion of a control architecture and apparatus for machine automation including a programmable interface module 315 and a programmable interface circuit 440, according to some implementations of the present invention. [Figure 4A] 1 illustrates an example of interconnections for a flex I / O controller package including a programmable interface module, an analog-to-digital converter, a digital-to-analog converter, and an isolated communication controller. [Figure 4B] 3 illustrates an example of a programmable interface module, where the module can include multiple programmable interface circuits, each of which can include programmable analog I / O circuitry and programmable digital I / O circuitry, according to some implementations of the present invention. [Figure 5A] 4C illustrates an example of a programmable analog I / O circuit according to some implementations of the present invention that can be used in the programmable interface module shown in FIG. 4B. [Figure 5B] 4C illustrates an example of a programmable digital I / O circuit according to some implementations of the present invention that can be used in the programmable interface module shown in FIG. 4B. [Figure 5C] 4C illustrates an example of a programmable signal routing / isolation circuit according to some implementations of the present invention that can be used in the programmable interface module shown in FIG. 4B. [Figure 5D] 4C illustrates an example of a programmable bias circuit according to some implementations of the present invention that can be used to program voltage supply levels in the programmable interface module shown in FIG. 4B. [Figure 5E] 4C illustrates another example of a programmable digital I / O circuit that can be used in the programmable interface module shown in FIG. 4B, according to some implementations of the present invention. [Figure 6A] 4C illustrates another example circuit for implementing programmable analog I / O signaling in the programmable interface module shown in FIG. 4B, according to some implementations of the present invention. [Figure 6B] 4C illustrates another example circuit for implementing programmable analog I / O signaling in the programmable interface module shown in FIG. 4B, according to some implementations of the present invention. [Figure 7] 1 illustrates method-related operations according to some implementations of the present invention for automated / semi-automated control of machines. DETAILED DESCRIPTION OF THE INVENTION

[0011] The following is a detailed description of various concepts related to the present input / output method and apparatus for monitoring and / or controlling a dynamic environment, and implementations of the method and apparatus. It should be understood that the various concepts discussed herein may be implemented in many ways. Examples of specific implementations and applications are provided herein primarily for illustrative purposes.

[0012] In particular, the figures and the implementation examples described above and below are not intended to limit the scope of the present disclosure to the implementation examples discussed herein. Other implementations are possible by replacing at least some of the elements described or shown. Furthermore, where certain elements of the disclosed implementations can be exemplified, partially or completely, using known components, in some cases, only those portions of such known components necessary for understanding the implementation will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the distinctive inventive concepts underlying the implementations.

[0013] FIG. 1 depicts a simplified example of a portion of a conventional control architecture and apparatus for automating a machine 150, as may be implemented in, for example, a manufacturing facility. In FIG. 1, a programmable logic controller (PLC) 105 may send and receive signals to at least one signal transformer 110-1 for ultimate communication with components of the machine 150. While only one PLC is shown, it should be understood that multiple such PLCs (e.g., tens or hundreds of PLCs in some implementations) may be located at various locations within the manufacturing facility. In some cases, each PLC may be coupled to multiple signal transformers 110-1, 110-2, ..., which in turn couple to components 120, 130, 140 within the automated / semi-automated machine 150 via one or more wiring harnesses 115.

[0014] 1, for purposes of illustration, machine 150 is shown as including three exemplary components: sensor 120, stepper motor 130, and thermal control device 140 (heater and / or cooler). In actual applications, machine 150 (and other machines in a manufacturing facility) may have fewer, more, and / or different types of components coupled to programmable logic controller 105 (although generally, at least one or more sensors 120 are typically included in machine 150). The components of machine 150 operate in a dynamic environment in response to command signals and / or detected signals. The operation of one component may depend on the operation of another component and / or changes in the dynamic environment detected by one or more sensors 120.

[0015] In an implementation similar to that shown in FIG. 1 , programmable logic controller 105 may connect to and communicate with multiple signal transformers 110-1, 110-2, ... 110-N via multiple interconnects 108. Signal transformers may be designed to handle specific types of signaling, and the signal transformer design may be different for each type of signaling. For example, there may be a first signal transformer 110-1 for analog first type of signaling and a second signal transformer 110-2 for digital first type of signaling. There may be a third signal transformer for analog second type of signaling that is different from the first type of signaling, and so on. Each signal transformer may have multiple pins (e.g., physical conductive interconnects for input / output signal channels) that may be used to directly connect wires and / or cables 113 to wiring harness 115, as described. The programmable logic controller 105, signal transformer 110 and wiring harness 115 may appear as shown in the photograph of Figure 2A. Typically, there may be a different number of wires and / or cables 113 connected to the signal transformer and to each component of the machine 150.

[0016] FIG. 2B shows an example of the congestion of wiring that can occur when connecting to an equipment rack 210, which is barely visible in the photograph. Equipment racks and / or electronics cabinets are often used to install programmable logic controllers 105, signal transformers 110, wiring harnesses 115, and other interface devices for automated machines. Some automated / semi-automated manufacturing machines may require numerous racks containing numerous programmable logic controller signal transformers and wiring harnesses and complex cabling (e.g., daunting amounts of interconnecting cables and custom cable harness sets). When numerous programmable logic controller signal transformers and wiring harnesses are installed in an equipment rack 210, the rack can become very congested with cabling, making inspection very difficult. In addition to the complexity of the initial installation, troubleshooting or repairing such equipment can be a very complex, time-consuming, and expensive undertaking. In some cases, the racks, cabling, harnesses, and PLCs may be assembled and housed in several large and expensive electrical cabinets to form the equipment shown in FIGS. 2A and 2B.

[0017] Challenges in machine automation can include reliably connecting, coordinating, and controlling several disparate components in an automated / semi-automated machine, often at fairly high operating speeds. Overcoming such challenges can add significant engineering time, complexity, and cost to the machine, as previously discussed. This challenge can be even more difficult in new machine designs. Depending on the application, power and communication standards may at least partially constrain the range of system complexity. Nevertheless, the task of aligning numerous power and / or communication standards, coupled with the presence of numerous disparate machine components and their respective power and communication / signaling requirements, can necessitate significant time, effort, and cost.

[0018] Applicant recognizes and understands that the complexity of combining disparate components in systems for automation involving manufacturing machines in various factory environments can also limit the reliability of the resulting systems, leading to less uptime and significant repair / maintenance costs. Such reduced reliability can mean that using some automated, conventional, heterogeneous component systems makes operating the machines more dangerous (e.g., increasing the risk of downtime and costs associated with repairs).

[0019] The process of devising the arrangement of components in an automated / semi-automated machine, assembling those disparate components, and ensuring all of those components function properly requires significant human resources, in some cases exceeding the part costs of the machine itself. Applicant also recognizes and understands that such prohibitive economics are a significant constraint on the use of automation in automated / semi-automated machines. Some or all of the aforementioned complexity, risk, and cost factors may limit consideration of machine automation in various areas of economic activity where automation may be applied (e.g., beyond automated / semi-automated factory environments). Such areas may include, but are not limited to, workplaces, homes, autonomous vehicles, advanced automobiles, communication systems, systems that handle or process fluids, waste treatment facilities, power plants, gas distribution networks, and / or electric power grids.

[0020] In further considering the interconnection of various machine components, Applicant also recognizes and understands that a number of industrial Ethernet standards have been developed and effectively deployed to control machine components (sometimes referred to as "peripherals"). While some components or peripherals may be controlled according to such industrial Ethernet standards, other machine components may require relatively simpler control interfaces, examples of which include, but are not limited to, control interfaces that support signaling via single-ended connections, binary voltage-based differential connections, and current-based differential connections, and analog current / voltage signals. For various reasons, most, if not all, of these connections must maintain electrical isolation between components while allowing the free flow of data, and sometimes power, as well.

[0021] In view of the potential complexity of wiring and connecting many different components for machine automation, applicant has recognized and understood that some of the above-mentioned challenges associated with machine automation may be alleviated using programmable interface circuits / modules. Applicant has recognized and understood that an important part of rapidly deploying cheaper and more reliable automated / semi-automated machines involves improving the integration of at least some basic system components, making greater use of networking and distributed control (e.g., as opposed to power and control being in large centralized electrical cabinets with complex cabling), and utilizing adaptive, programmable interface circuits for input / output signaling.

[0022] In light of the foregoing, FIG. 3 depicts a portion of an equipment and control architecture for an automated / semi-automated machine that provides improved integration and networking of system components and adaptive, programmable interface circuitry for input / output signaling. In FIG. 3, a system controller 301 provides various control and programming signals and receives information from one or more components of the machine 350. In some implementations, the system controller 301 communicates over one or more serial communication channels, wired, or wireless links 305. Examples of controllers that function as the system controller 301 include, but are not limited to, a PLC, a personal computer, a laptop computer, a microprocessor, a microcontroller, a distributed machine controller, or some combination thereof. In one exemplary implementation, the system controller 301 may include a Maestro 16, a product of Opteon, Inc., Cambridge, Massachusetts, USA. Current information about the Maestro 16 controller is available at www.opteontech.com / seamless-systems / beyond-plcs. The inventive technology used by Maestro 16 is described in U.S. Patent No. 9,459,607, entitled "Methods, Apparatus, and Systems for Monitoring and / or Controlling Dynamic Environments," filed October 4, 2016, which is incorporated herein by reference in its entirety. Among other advantages, using Maestro 16 as the system controller 301 provides a compact, cost-effective, and very low latency control solution for machine automation.

[0023] 3 , the isolated communications controller 310 can transmit and receive signals to and from the system controller 301 via a wired or wireless link 305. The isolated communications controller 310 can provide electrical isolation (e.g., voltage and current isolation) between the link 305 and the plant wiring that ultimately connects to the machine 350. In some implementations, the isolated communications controller 310 can receive time-multiplexed serialized signals from the system controller 301, electrically isolate the received signals, and convert the serialized isolated signals into parallel programming voltages that are applied to the programmable interface modules 315 to program the operating modes of the modules 315, as described further below. Additionally, the isolated communications controller 310 can receive parallelized data from one or more programmable interface modules 315, serialize the data, and electrically isolate the serialized data for transmission to the system controller 301 via the link 305. The isolated communications controller 310 may use signal multiplexers to convert serial signals to parallel signals and vice versa, and may use opto-isolators and / or other opto-isolation circuit components to achieve electrical isolation.

[0024] With respect to the adaptive programmable interface circuitry, the isolated communications controller 310 can be connected to a programmable interface module 315, including programmable interface circuits 440, 580, as described further below, to provide control signals, power, and / or receive input signals of different types of signaling from a variety of components within the automated / semi-automated machine 350. An advantageous aspect of the programmable interface module 315 and its circuitry is that it includes one or more adaptive signaling channels (so-called “flexible I / O” channels), each of which can be programmed to transmit and / or receive different types of analog and digital signals. The combination of the isolated communications controller 310 and the programmable interface module 315, referred to herein as a “flex I / O controller” 450, allows for electrical isolation and diverse signaling with one or more components within the machine 350, each using a different type of signaling. In different implementations of the flex I / O controller 450, the programmable interface module 315 may be incorporated as a circuit in the same package with the isolated communications controller 310, or may be packaged as a separate module that can be installed in close proximity to the isolated communications controller.

[0025] In one embodiment, flex I / O controller 450 enables system controller 301 to be compatible with almost any component or device of machine 350 to which programmable interface module 315 can be connected. According to some implementations of the invention described below, the same type of cables and connectors can be used between each interface module 315 and the breakout box 318 to which the component or interface module is connected. Compared to the conventional system implementations shown in Figures 2A and 2B, flex I / O controller 450 therefore offers a highly robust solution to the problem of intricate and complex wiring arrangements, requiring numerous signal transformers, each of which presents various challenges associated with such arrangements, including vulnerability to breakage or other damage and significant difficulty in resolving breakage and other damage.

[0026] As shown in FIG. 3 , programmable interface module 315 can be interposed between isolated communications controller 310 and one or more components 320, 325, 330, 340 of machine 350. According to some implementations, programmable interface module 315 can be configured to interface with up to 16 machine components. However, in some cases, programmable interface module 315 can be configured to interface with any suitable number of components (e.g., 2, 4, 5, 6, 8, 9, 10, 12, 16, 20, 32, etc.). For example, as discussed in more detail below in connection with FIG. 4B , programmable interface module 315 can include N copies of programmable interface circuit 440 used to connect between isolated communications controller 310 and the machine components. In some cases, programmable interface module 315 can further include M copies of different implementations of programmable interface circuit 580 used to connect between isolated communications controller 310 and the machine components. The values ​​of N and M may be the same or different positive integers between 1 and 50 in some implementations.

[0027] The machine automation apparatus may also include a breakout box 318 to which a programmable interface module 315 is connected. One programmable interface module 315 may connect to one or more breakout boxes 318 using additional cables 319. According to one implementation, each cable 319 from the interface module 315 may support flexible I / O signaling with up to four machine components and connect to one breakout box 318. Another cable 314 may extend from the breakout box 318 to each of the components 320, 330, and 340.

[0028] The programmable interface module 315 can include one or more signal ports 317 to which one or more cables 319 are connected. The signal ports 317 can include multiple conductive interconnects for transmitting different types of analog and / or digital signals, as well as power and reference potentials. According to one implementation, there can be up to four or more signal ports 317 on the programmable interface module 315, thereby enabling the programmable interface module to provide flexible I / O signal channels to up to 16 machine components, although there can be interface modules and signal ports 317 corresponding to signal communication with fewer or more machine components.

[0029] In some implementations, the same type of connector (male or female) can be used for each signal port 317 and the corresponding mating connector used to terminate each cable 319, 314. According to some implementations, the cables 319 can all be the same type for each signal port and each programmable interface module 315. In some cases, the cables can be 8- or 12-wire Ethernet cables or industrial Ethernet cables (e.g., CAT5 or CAT6 series cables) having standard Ethernet or industrial Ethernet connectors (e.g., RJ-45, M8, or M12 male or female plugs) that plug into standard receptacles (e.g., RJ-45, M8, or M12 female or male receptacles) on the programmable interface module 315. Thus, various connection devices (such as wires and wiring harnesses) can be significantly simplified, reduced, or eliminated using the programmable interface module 315 of this implementation.

[0030] It will be understood that some implementations may use cables and connectors other than Ethernet cables or may use cables and connectors with a different number of signal lines. In some cases, one or more wireless links may be implemented between the programmable interface module 315 and one or more components of the machine and / or the controller 310. Additionally or alternatively, different types of cables and connectors may be used for a single programmable interface module 315 with adaptable I / O signaling capabilities.

[0031] According to some implementations, there may be a data power interconnect 401 between the programmable interface module 315 and the isolated communications controller 310. Such an interconnect may be contained within a package or enclosure that includes both the isolated communications controller and the programmable interface module. Alternatively, if the controller 310 and interface module 315 are packaged separately, the data power interconnect may be created using one, two, or more multi-wire cables and connectors.

[0032] As mentioned above, the use of a flex I / O controller 450 including a programmable interface module 315, as shown in FIG. 3 and implemented as described herein, can significantly reduce or eliminate the need for various separate signal transformers 110, complex wiring harnesses, various connectors and cables, and matching components typically required within conventional automated / semi-automated machine architectures. An example of such reduction can be envisioned by comparing the architecture of FIG. 3 with that of FIG. 1. As described in more detail below, automation complexity can be reduced by the programmable interface module 315, which can essentially enhance the functionality of the input / output channels of the isolated communications controller to allow adaptive (“flexible”) control of the channels to handle different types of analog and digital signals. The adaptability of such input / output channels is sometimes referred to herein as “flex I / O,” “adaptive I / O signaling,” or “adaptive I / O channels.”

[0033] A number of such isolated communication controllers 310 and programmable interface modules 315 with flex I / O signal channels can be used together as a network of isolated communication controllers to control automated / semi-automated machines for manufacturing or other automated applications, significantly reducing the complexity associated with interconnecting machine components and improving operational reliability with low latency. Such automated / semi-automated applications include, but are not limited to, manufacturing facilities, workplaces, homes, autonomous vehicles, advanced automobiles using multiple processors and electronic control modules, communication systems, systems that handle or process fluids, waste treatment facilities, power plants, gas distribution networks, and / or electric power grids.

[0034] FIG. 4A illustrates an example of a flex I / O controller 450 in which the isolated communications controller 310 is packaged with at least one programmable interface module 315. The diagram shows further details of several interconnects 401 between the programmable interface module 315 and the isolated communications controller 310. The interconnects 401 may include multiple wires (e.g., ribbon cables) for multiple interconnects 401 on each programmable interface circuit 440. According to some implementations, digital input lines (DIN) from the programmable interface circuits 440, 580 may be connected directly to the isolated communications controller 310. In some cases, analog input (AIN) and analog output (AOUT) lines may be provided to an analog-to-digital converter (ADC) 480 and a digital-to-analog converter (DAC) 482, respectively, where conversion to and from digital signals can occur for communication with the controller 310.

[0035] 4B, an example of a programmable interface module 315 is depicted using a simplified block diagram. The programmable interface module 315 controls a supply voltage +V DC, 401. In some implementations, the programmable interface module 315 may include one or more programmable interface circuits 440, 580, each including a programmable analog input / output circuit 410 and a programmable digital input / output circuit 420. The analog I / O circuit 410 and the digital I / O circuit 420 may receive signals from and transmit signals to the isolated communications controller 310 using at least some of the conductive interconnects 401. The programmable interface module 315 may also include a programmable signal routing / isolation circuit 430. Output signals generated by the analog I / O circuit 410 and the digital I / O circuit 420 may be directed to one or two output conductive interconnects 452, 454 (labeled ADIO and DIFF, respectively) at the signal port 317 using the signal routing / isolation circuit 430 in some implementations. In some cases, the signal routing / isolation circuitry 430 can be programmed so that one of the output interconnects (e.g., interconnect 452) provides single-ended signaling with respect to ground or other reference potential. In some cases, the signal routing / isolation circuitry 430 can be programmed so that one of the output interconnects (e.g., interconnect 454) provides a resistive path to ground or a fixed reference voltage or ground, allowing single-ended signaling on the other output interconnect. In some implementations, the signal routing / isolation circuitry 430 can be programmed to enable differential signaling between the two output interconnects 452, 454.

[0036] In some implementations, the programmable interface module 315 can include multiple copies of a single version of the programmable interface circuit 440 (e.g., copies of circuits 410, 420, 430), with each programmable interface circuit capable of communicating with one or more machine components. In some implementations, there can be at least four copies of the programmable interface circuit 440 in the programmable interface module 315, such that the programmable interface module 315 has four signal channels (up to eight conductive interconnects 452, 545) for communicating with four machine components using an eight-wire cable 319. Therefore, standard industrial M8 or M12 cabling can be used to connect to the interface module 315. However, the programmable interface module 315 of the present invention is not limited to four copies of the interface circuit 440 and standard M8 or M12 cabling. In some cases, the programmable interface module 315 can have fewer or more than four copies of the programmable interface circuit 440.

[0037] In some cases, there may be two or more different versions of copies of the programmable interface circuit 440, 580 in the programmable interface module 315. An example of such an implementation is described below in connection with Figure 5E.

[0038] Further details of an exemplary programmable analog I / O circuit 410 are shown in FIG. 5A. In some implementations, the programmable analog I / O circuit 410 includes a first multiplexer 510, a second multiplexer 515, a switchable analog output driver 520, a current sensor 530, and a switchable receiving signal driver 540. The first multiplexer 510, the output signal driver 520, and the current sensor 530 can be connected to form a programmable or switchable output signal driver that outputs a signal with a voltage level encoding (e.g., acting as a voltage source) or a current level encoding (e.g., acting as a current source). Thus, the programmable analog I / O circuit 410 can output either an analog voltage-derived signal or an analog current-derived signal. The receiving signal driver 540 can be programmed to receive a single-ended analog signal or a differential analog signal.

[0039] In some implementations, first multiplexer 510 can be embodied as a multiplexing chip 512 that can be programmed (via interconnect AMODE) to select one of two input signals (IN1, IN2) to provide at its output. An example of such a chip is the SN74LVC1G3157, a single-pole, double-throw analog switch configured for multiplexing operation, available from Texas Instruments, Dallas, Texas. However, other multiplexing circuits can also be used in some cases. For example, a general-purpose field-effect transistor (FET) can be used to controllably switch one of the two signals onto a common output line. When multiplexing chip 512 is used, the output from the chip can be connected, for example, to the non-inverting terminal of operational amplifier 522 in output signal driver 520. A programmable "select" input (shown connected to a conductive interconnect labeled AMODE) of the multiplexing chip can be used to program the programmable analog I / O circuit 410 for operation in an analog voltage mode (e.g., essentially a voltage-derived output) or an analog current mode (e.g., essentially a current-derived output). The voltage-derived output or current-derived output can be provided to interconnect P3 in the schematic diagram of FIG. 5A, which can be coupled to a circuit (shown in FIG. 5C) having interconnect P3 to control the voltage or current at first output interconnect 452 (ADIO). In some implementations, the conductive interconnect in the diagram can be embodied as a conductive trace or pad on a printed circuit board, a wire, or a pin of a connector, or some combination thereof.

[0040] The first input IN1 of the multiplexing chip 512 of the first multiplexer 510 can carry a signal proportional to the current level flowing through the first output interconnect 452 (ADIO). The current level is determined by a voltage or current source +V DCThe current can be detected by a current sensor 530 having a current sensing chip 532 positioned to detect current flow on a line connected between the first output interconnect 452 (interconnect P1 in FIGS. 5A and 5C in a circuit implementation). An example of a current sensing chip 532 is the LT6106 current sensing chip, formerly sold by Linear Technologies Corporation of Milpitas, California, but now available from Analog Devices, Inc. of Norwood, Massachusetts. However, other current sensing circuits (e.g., sensing circuits using general-purpose operational amplifiers instead of dedicated chips) can also be used. According to the implementation shown in FIG. 5A, a resistor R3 is placed in the power supply line that supplies power to the first output interconnect 452 via interconnect P1. A voltage difference across resistor R3 can be detected to provide a signal proportional to the current flowing through (e.g., sourced or sunk into) the first output interconnect 452. A second input IN2 of the multiplexing chip 512 can carry a signal proportional to a voltage level at a first output interconnect 452 (ADIO) of the programmable interface circuit 440. For example, the second input IN2 can be coupled to the first output interconnect 452 using interconnect P2 (e.g., connected via one or more resistors R14 and the receiving signal driver 540).

[0041] Selecting a signal from the first input IN1 or the second input IN2 can provide either current level detection or voltage level detection in the feedback circuit path to the non-inverting terminal of the operational amplifier 522 in the analog output signal driver 520. Thus, the output signal driver 520 can be switched between two different feedback loops. When voltage level detection is used (the IN2 input is selected), the analog I / O portion of the programmable interface circuit 440 can operate in voltage-to-voltage mode. In such a case, the output voltage from the amplifier 522 is proportional to the input voltage provided to the inverting terminal of the amplifier (e.g., via a conductive interconnect labeled AOUT). In some cases, the isolated communications controller 310 can provide an analog signal directly to AOUT (e.g., the isolated communications controller can include an on-board DAC). In other cases, a digital-to-analog converter (DAC) can be used (between the isolated communications controller and the interface module depicted in FIG. 4A or at the front end of the interface module 315) to convert the digital signal from the isolated communications controller 310 to the analog signal provided to AOUT.

[0042] When current level detection is used (IN1 input is selected), the analog I / O portion of the programmable interface circuit 440 can operate in current output mode. In such a configuration, the output current from the amplifier 522 is proportional to the input voltage provided to the amplifier's inverting terminal via AOUT. The input voltage can be received from the isolated communications controller 310 or the DAC described above.

[0043] A further feature of programmable interface circuit 440 is that it can receive analog signals on at least first output interconnect 452 (ADIO via interconnect P2) and provide the received analog signals to isolated communications controller 310 (e.g., via interconnect AIN) as shown in FIG. 4A or to an analog-to-digital converter (ADC) that provides a corresponding digital signal to controller 310. A switchable receive signal driver 540 can be used to monitor the output signal provided to first output interconnect 452 (ADIO) for single-ended analog signals, or to both output interconnects 452, 454 (ADIO and DIFF) for differential analog signals. For example, a second multiplexer 515 with multiplexer chip 512 can be used to switch between inputs IN1 and IN2, thereby providing different configurations of receive driver op-amp 542. When the first input (IN1) is selected based on a signal applied to the interconnect (ADIFSEL), the inverting terminal of the operational amplifier 542 can be connected to a reference potential (e.g., ground). In this configuration, the operational amplifier operates as a single-ended, non-inverting amplifier for signals detected through the interconnect P2, which is connected to the first output interconnect (ADIO). When the second input (IN2) is selected, the inverting terminal of the operational amplifier can be connected to the second output interconnect 454 (DIFF). In this configuration, the operational amplifier 542 functions as a differential amplifier for differential analog signals appearing between the output interconnects (ADIO and DIFF). In some cases, the select pin of the second multiplexer 512 (shown connected to the interconnect labeled ADIFSEL) can be connected instead to the interconnect (labeled RXEN) of the transceiver 570 (shown in FIG. 5B), avoiding an extra interconnect.

[0044] The output from the operational amplifier 542 of the switchable receiving signal driver 540 can be provided to an interconnect (AIN) that provides a signal to the isolated communications controller (or to an ADC that provides a signal to the isolated communications controller as depicted in FIG. 4A ). When an analog signal is received or detected, the first output interconnect 452 can be isolated from the output of the operational amplifier 522 of the output signal driver 520 and the digital I / O circuit 420, as described in further detail below in connection with the programmable signal routing / isolation circuit 430.

[0045] An example of a programmable digital I / O circuit 420 is shown in FIG. 5B. According to some implementations, the digital I / O circuit 420 includes an adjustable high-level logic driver 550, a low-level logic driver 560, and a transceiver 570. The high-level logic driver 550 and the low-level logic driver 560 can be used to provide single-ended logic signals on the first output interconnect 452 (ADIO). The transceiver 570 can be used to provide single-ended logic signals on the first output interconnect 452 or differential logic signals on the first output interconnect 452 (ADIO) and the second output interconnect 454 (DIFF), and can also be used to receive single-ended and differential logic signals.

[0046] Due to the versatility of the analog and digital I / O circuits, the programmable interface circuit 315 can, in some implementations, support standardized network communications. For example, one or more digital signal channels can be programmed to support RS-485 communications according to a standard signaling protocol. As a more specific example, the digital I / O circuit 420 can be programmed to support linear bus technology using two interconnects 452, 454 for a two-wire RS-485 networking channel. Alternatively, two digital I / O circuits 420 can be programmed to support a four-wire, full-duplex RS-485 networking channel. Other networking protocols that can be supported by the programmable interface module include, but are not limited to, Profibus and CAN bus.

[0047] According to some implementations, adjustable high-level logic driver 550 may be implemented with a current mirror 552 and a relay driver 554. The current mirror and relay driver may be coupled to any suitable voltage +V DC 5C ) on the first output interconnect 452. In this manner, the current mirror 552 and relay driver 554 can drive a transistor 584 (through interconnect P4) that switches a high logic value received from the isolated communications controller 310 (e.g., at the conductive interconnect labeled DOUTP) to any voltage level +V appropriate for the components of the machine 350 to interpret as a high logic level. DC The component can be connected to a first output interconnect 452. In some implementations, a voltage value +V DCmay be user-programmable, as described below in connection with FIG. 5D. Other implementations for high-level logic driver 550 are possible. In some cases, the output from isolated communications controller 310 may be sufficient to drive transistor 584 directly, and current mirror 552 and relay driver 554 may not be necessary. In some implementations, the current mirror and relay driver may be replaced with an amplifier, a line driver, a buffer, or some combination thereof.

[0048] In some implementations, the low-level logic driver 560 may be implemented in part by a transistor 562. The transistor may be configured to switch a low-level reference voltage, such as ground potential, onto the first output interconnect 452 (via interconnect P2) in response to a signal received from the isolated communications controller 310 (e.g., via conductive interconnect DOUTN). In some cases, a resistor R17 and a second transistor T8 may be used in combination with the transistor 562 to define a pull-down current safe for voltages that would be interpreted as a low logic level by components connected to the first output interconnect 452. In some cases, the low-level logic driver 560 may be used to invert a logic signal from the isolated communications controller. For example, the transistor 562 may be an n-FET that is turned on with a positive voltage, turning on transistors 582 and 584 (FIG. 5C). In such a configuration, the logic signal driving the transistor 562 is inverted at the first output interconnect 452. When transistor 562 is turned off, it can effectively isolate the circuitry of low-level logic driver 560 from first output interconnect 452 .

[0049] Transceiver 570, in some implementations, may be implemented with a transceiver chip 572. An example of a transceiver chip is the LTC2876 transceiver chip, formerly sold by Linear Technologies Corporation of Milpitas, California, but now available from Analog Devices, Inc. of Norwood, Massachusetts. Such a transceiver chip can provide user-selectable single-ended or differential digital transmission and reception on two output interconnects (TR1, TR2). In some cases, the transceiver chip 572 can be used to transmit and receive digital signals at 5-volt logic levels or 3-volt logic levels. The logic signal levels can be set, for example, by the voltage level applied to the transceiver's VCC supply pin. The transceiver 570 can have programmable input interconnects (labeled TXEN and RXEN) that can be connected to the isolated communications controller 310, where TXEN can be used to program the transceiver to transmit digital signals and RXEN can be used to program the transceiver to receive digital signals. The transceiver 570 can also include digital data interconnects (labeled DIN and DOUT) that can be connected to the isolated communications controller 310. The digital data interconnect DIN can be used to transmit digital data received from components of the machine 350 to the isolated communications controller 310. Digital data interconnect DOUT can be used to transmit digital data received from isolated communications controller 310 to components of machine 350. A dedicated transceiver chip 572 may be used in some implementations, while in other implementations transceiver 570 can be made from more basic circuit components (such as packaged transistors, resistors, etc.).

[0050] Digital I / O circuit 420, according to some implementations, may include a shunt switch (e.g., transistor 586) connected between first output interconnect 452 (via interconnect P2) and a reference voltage (ground in the illustrated example). Optionally, a low-impedance resistor R4 may be included in series with the current-carrying terminal of transistor 586. This transistor may be used to provide a low logic level value on the first output interconnect. This transistor can also be used to provide a low impedance sink for current received from first output interconnect 452 (e.g., when receiving an analog signal from a sensor). For example, the value of resistor R4 can be anywhere between 10 ohms and 500 ohms. The low impedance path can be useful in current sensing or current-encoded communication operations, and in measuring differential analog voltages.

[0051] In some implementations, the digital I / O circuit 420 may further include a second shunt switch (e.g., a transistor not shown) connected between the second output interconnect 454 (DIFF) and a reference voltage (e.g., ground). This second shunt switch may be used, for example, to provide a reference voltage on the second output interconnect 454 for single-ended transmission or reception. The digital I / O circuit 420 may include interconnects P2, P4, and P5 that connect with corresponding interconnects of the analog I / O circuit 410.

[0052] FIG. 5C illustrates an example of a programmable signal routing / isolation circuit 430 that can be implemented in the programmable interface circuit 440. According to some implementations, the routing / isolation circuit comprises a plurality of transistors configured to switch analog or digital signals onto a first output interconnect 452 (ADIO) and / or isolate analog / digital circuits from the first output interconnect 452. For example, a first transistor 582 can be configured as an amplifier to drive an analog signal on the first output interconnect 452 when the analog signal is input to the analog I / O circuit 410 (e.g., received from the isolated communications controller 310 at interconnect AOUT and output to interconnect P3 by the analog signal driver 520 of FIG. 5A). The first transistor 582 can be a power FET, such as a Siliconix Si3459BDV power MOSFET, available from Vishay Intertechnology, Inc. of Malvern, Pennsylvania. When a digital signal is provided to the first output interconnect 452, the first transistor 582 can be turned on, thereby providing a voltage to the second transistor 584 of the routing / isolation circuit 430.

[0053] A second transistor 584 (which may also be a power transistor and may be of the same model as the first transistor 582) may be used to drive a logic signal on the first output interconnect 452. For example, a logic signal applied to the input of the high-level logic driver 550 (e.g., provided at interconnect DOUTP in FIG. 5B) may be converted to a voltage and switched on the first output interconnect 452 by the second transistor 584.

[0054] When signaling is not provided by either the analog I / O circuit 410 or the high level logic driver 550, the first transistor 582 and the second transistor 584 are turned on to provide a high voltage level +V DCto the first output interconnect 452. In this configuration, according to some implementations, the digital signal interconnect DOUTN and the low-level logic driver 560 can be used to drive an inverted logic signal on the first output interconnect 452.

[0055] The transistors of the programmable signal routing / isolation circuit 430 and the transistor 562 of the low-level logic driver 560 can, in some cases, be thought of as isolation switches. For example, when the associated one of these transistors is in an off state, that transistor can isolate the first output interconnect from analog circuitry, digital circuitry, and / or voltage levels associated with the analog and digital circuitry. The use of these transistors, according to some implementations, enables adaptive I / O signaling (transmission and reception) of different types of digital and analog signals through the same signal channel with one or two output interconnects 452 (ADIO), 454 (DIFF).

[0056] As previously mentioned, the +V DC Ya-V DC 5D shows an example of a programmable bias circuit 405 for programming the supply voltages for any one or combination of the circuit portions described above. In some implementations, the programmable bias circuit 405 may provide a bias voltage +V DCThe circuit may include a first terminal 591 configured to receive a first bias voltage (+24V in the illustrated example) and a second terminal 592 configured to receive a second bias voltage (+5V in the illustrated example), connectable to an output bias terminal 598 providing a bias voltage. Other bias values ​​may be used for other implementations. A first transistor 593 may be used to connect the first terminal having a higher bias value to the output bias terminal 598. A Zener diode D8 may be used to effectively isolate a lower bias power supply from the output bias terminal when a higher bias power supply is connected to the output terminal. In some cases, a second transistor 595 may be used to turn the first transistor 593 on or off (e.g., when the gate voltage required by the first transistor is higher than the gate voltage provided by the logic driver of the isolation communication controller). The bias value may be selected by setting or clearing a logic input (labeled VDSEL). While only two bias values ​​selectable by a single programmable logic input are shown, additional bias values ​​may be selected, for example, by adding more transistors, bias input terminals, and programmable logic inputs.

[0057] Some example voltage bias values ​​that can be used to operate the programmable interface module 315 and its interface circuitry 440 include, but are not limited to, 24V DC, 5V DC, and 3.3V DC. In some implementations, the programmable interface module 315 may include power supply circuitry and / or components to generate bias voltages internally and independently of the isolated communications controller. In such implementations, the programmable interface module 315 may locally share the ground reference of components connected to the interface module via wires in the interconnect cables 319, 314 local to the machine to avoid ground differences that may occur throughout the larger area of ​​the machine. In some cases, the programmable interface module 315 may also or alternatively locally share one or more bias power supplies with components connected to the interface module via one or more wires on the interconnect cables local to the machine.

[0058] 4B , it will be appreciated from the above description of programmable analog I / O circuit 410, programmable digital I / O circuit 420, and programmable signal routing / isolation circuit 430 that interface circuit 440 can be configured or programmed to handle different types of analog and digital signaling through various configurations on interconnect 401. Some example configurations are described next. Those skilled in the art will appreciate that the configurations described depend on the type and / or number of transistors used to implement the isolation switches in interface circuit 440. Therefore, the configurations may differ if different types and / or different numbers of transistors are used to implement the isolation switches.

[0059] For transmission of analog signals to components of machine 350, second transistor 584 can be in an on (i.e., conductive) state that allows the analog signal to pass to first output interconnect 452 (e.g., DOUTP is set to a logic high value), shunt transistor 586 can be in an off (i.e., non-conductive) state that isolates the reference potential (ground in the implementation shown) from first output interconnect 452 (interconnect CURSINK is cleared to a logic low value), and transistor 562 of low-level logic driver 560 can be in an off state that isolates the low-level logic driver circuitry from first output interconnect 452 (DOUTN is cleared to a logic low value). It will be understood that transmission of analog signals can be in current mode or voltage mode, according to the mode selection (made on interconnect AMODE) discussed above. Additionally, analog data can be transmitted as a time-varying signal by applying such a signal to interconnect AOUT by isolated communications control device 310, as a static DC value, or as a time-varying signal superimposed on a DC value (e.g., serial data superimposed on a DC current).

[0060] To receive the analog signal, the high-level logic driver 550 circuit, the amplifier 520, the current sensor 530, and the supply +V DCAt least the second transistor 584 can be turned off (DOUTP cleared to a low logic value) to isolate the analog signal from the first output interconnect 452. Optionally, the first transistor 582 can also be turned off (AOUT cleared to a low or zero voltage level). The transistor 562 of the low-level logic driver 560 can be turned off upon receiving an analog signal. Optionally, the shunt transistor 586 can be turned on (CURSINK set to a logic high value) to sink an analog current upon receiving an analog signal based on the received current. Alternatively, the third transistor 586 can be turned off (CURSINK set to a logic low value) upon receiving an analog signal based on the received voltage. Additionally, the analog data can be received as a time-varying signal, as a temporarily static value, or as a time-varying signal superimposed on a temporarily static value. The temporarily static value can be no change in value for a period of 1 microsecond to 10 seconds.

[0061] When a time-varying signal is superimposed on a temporarily static value, appropriate digital filtering by the isolated communications control device to receive the analog signal allows DC current or DC voltage information to be read while also reading the serial digital information superimposed on the DC current or DC voltage. In some implementations, the serial digital information may be superimposed on the transmitting and / or receiving signals as a ±1 mA modulation of a DC current in the range of 4 mA to 20 mA. Data superimposed at baud rates of 300 baud to 230.4 kbaud and higher can be received and decoded by the isolated communications control device or machine components in some implementations.

[0062] When a transceiver chip 572, such as the LTC2876 transceiver chip, is used in transceiver 570, it may be desirable to place its outputs in a high impedance state while transmitting and receiving analog signals. For the LTC2876 transceiver chip, this can be achieved by tying the chip's receive enable pin (connected to interconnect RXEN in the implementation shown) to a high logic level and the chip's transmit enable pin (connected to interconnect TXEN in the illustration) to a low logic level. Different transceiver chips or transceiver configurations may require other settings.

[0063] The transmission and reception of differential signals via transceiver 570 involves the circuitry of high-level logic driver 550, amplifier 520, current sensor 530, and supply +V DC At least the second transistor 584 can be turned off (DOUTP cleared to a logic low value) to isolate the first output interconnect 452 (ADIO) from the first output interconnect 452 (ADIO). Optionally, the first transistor 582 can also be turned off (AOUT cleared to a low or zero voltage level). The transistor 562 of the low-level logic driver 560 can also be turned off (DOUTN cleared to a low logic value) to transmit a differential signal. The shunt transistor 586 can also be turned off (CURSINK cleared to a logic low value) to isolate the reference potential (ground in this example) from the differential signal lines (ADIO and DIFF).

[0064] The transmit and receive modes for differential digital signaling are established by setting the values ​​of pins on the transceiver chip 572. For example, if an LTC2876 transceiver chip is used in the transceiver, clearing its receive enable pin (connected to RXEN) to a logic low value and clearing its transmit enable pin (connected to TXEN) to a logic low value configures the transceiver to receive differential digital signals on the first output interconnect 452 (ADIO) and the second output interconnect 454 (DIFF) and provide corresponding digital signals at the chip's digital outputs (connected to interconnect DIN) to the isolated communications controller 310. Conversely, by setting the transceiver chip's receive enable pin to a logic high value and setting the transmit enable pin to a logic high value, the transceiver is configured to transmit the digital signal received from the isolated communications controller 310 at the chip's digital input (connected to interconnect DOUT) as a differential digital signal to the components connected to the first output interconnect 452 (ADIO) and the second output interconnect 454 (DIFF). Different transceiver configurations may require other settings.

[0065] Single-ended digital reception can be performed using transceiver 570, according to some implementations. For example, if an LTC2876 transceiver chip is used in the transceiver, the transceiver is configured to receive a single-ended digital signal on first output interconnect 452 (ADIO) by clearing its receiver enable pin (connected to RXEN) to a logic low value and clearing its transmitter enable pin (connected to TXEN) to a logic low value. Second transistor 584, third transistor 586, and optionally first transistor 582 may also be cleared to isolate their respective circuits. In this configuration, a logic high value indicates that the voltage level on first output interconnect 452 (ADIO) is equal to +V (in the implementation shown, on second output interconnect 454 due to voltage divider 567). DCA logic low value appears at the transceiver output (connected to DIN) when the voltage level on the first output interconnect 452 (ADIO) is greater than half the value of +V DC appears at the output of the transceiver (connected to DIN) when the signal is less than half the value of . If a current pull-up is required when receiving a single-ended digital signal from a transmitter, the first transistor 582 and the second transistor may be set to an ON state. If a current pull-down is required when receiving a single-ended digital signal from a transmitter, the transistor 562 of the low-level digital driver 560 may be set to an ON state.

[0066] Single-ended digital transmission can be achieved using high-level logic driver 550 and / or low-level logic driver 560 as previously described. The configuration of the interconnect to enable single-ended digital transmission will be apparent to those skilled in the art from the above description. When single-ended digital transmission is achieved, the output of transceiver 570 can be placed in a high impedance state as previously described. +V DC By selecting the voltage level for , single-ended digital transmission can be performed at a user-programmed logically high voltage level.

[0067] If desired, one or more of the interconnects 401 between the isolated communications controller 310 and the programmable interface module 315 may be electrically isolated to some degree from the output and / or other portions of the isolated communications controller. For example, the degree of electrical isolation may be provided using optoelectronic, capacitive, or inductive isolation, or some combination thereof (e.g., to isolate from unwanted DC voltages or currents and / or to prevent signal crosstalk).

[0068] In some implementations, two variations of the digital I / O circuitry can be used in the interface module 315. FIG. 5E depicts a variation of the digital I / O circuitry shown in FIG. 5B. The digital I / O circuitry 580 of FIG. 5E includes a high-level logic driver 550 and a low-level logic driver 560, but does not include a transceiver chip 572. Instead, the digital I / O circuitry 580 uses a pair of Zener diodes D20, D21 to maintain the received voltage at approximately 3 volts. The pair of diodes provides a robust means of converting the received single-ended digital signal from the very wide range of signal voltages output by the component transmitters to a digital input signal level appropriate for the isolated communications controller 310. In the example shown, the received single-ended digital signal can be stepped down to approximately 3 volts. By providing different supply voltages to the pair of Zener diodes, the received single-ended digital signal can be stepped down to other digital voltage values ​​(e.g., 5 volts, 1.8 volts, 1.5 volts, etc.).

[0069] 5E can be used in single-ended digital transmission and reception (e.g., when differential digital signaling is not required). Digital I / O circuitry 580 can be used with the analog I / O circuitry 410 described above in any interface circuitry 440 of programmable interface module 315.

[0070] In some implementations, alternative circuits may be used for portions of programmable interface module 315. Such alternative circuits are described in U.S. Provisional Patent Application No. 62 / 931,188, filed November 5, 2019, entitled "Input / Output Method and Apparatus for Monitoring and / or Controlling a Dynamic Environment," and in connection with Figures 4A, 4B, and 5 therein. In lieu of the analog circuitry of Figure 5A, alternative circuit examples for implementing analog I / O signaling are shown in Figures 6A and 6B.

[0071] 6A illustrates another example of a programmable analog I / O circuit 610 according to some implementations that can be used to send and receive analog signals between the isolated communications controller 310 and the components 320, 325, 330, and 340. The analog I / O circuit 610 can include a voltage-to-current converter 642 and multiple switches 652, 654, 656, and 658 (which can be implemented at least in part using transistors). In some implementations, the analog I / O circuit 610 can be combined with one or both of the analog-to-digital converter 480 and the digital-to-analog converter 482. If the isolated communications controller 310 can output and receive analog signals, the analog-to-digital converter 480 and the digital-to-analog converter 482 may not be used. According to some implementations, the analog I / O circuit 610 can include Zener diode voltage limiters on the two output interconnects 652 and 654 (AN1 and AN2) that can limit the amount of voltage that appears on each line (e.g., 24 V and 5 V in the illustrated example). The analog I / O circuitry 610 may further include resistors and capacitors for filtering, voltage regulation, current regulation, and / or current limiting.

[0072] When the circuit according to Figure 6A is used in the programmable interface circuit 440, it may replace the programmable analog I / O circuit 410 of Figure 5A. For example, the first multiplexer 510, the second multiplexer 515, the analog output signal driver 520, and the current sensor 530 may be removed and replaced with the circuit of Figure 6A. The receiving signal driver 540 may be removed or changed to a non-switched voltage follower or amplifier. Furthermore, the first transistor 582 of the programmable signal routing / isolation circuit 430 may be removed. A current-limiting resistor may be connected between the second transistor 584 and the voltage source +V DC6A can operate in conjunction with the programmable digital I / O circuit 420 of FIG. 5B. For example, a first output interconnect 632 (P2) of another programmable analog I / O circuit 610 can be connected to a first output interconnect 452 (ADIO) of the programmable interface circuit 440, and a second output interconnect 634 (DIFF) of the programmable analog I / O circuit 610 can be connected to a second output interconnect 454 (DIFF) of the programmable interface circuit 440.

[0073] More specifically, the voltage-to-current converter 642 can receive an analog voltage signal and output an analog current signal having a current value proportional to and representative of the analog voltage signal. The current converter 642 can drive a signal in a current loop using a mechanical component, potentially outputting a current level between 4 mA and 20 A, or approximately between those values. In some implementations, the current converter 642 can output a current level between 0.2 milliamps (mA) and 25 mA for signaling, or approximately between those values. An example of a current converter is the XTR117 current loop transmitter, available from Texas Instruments, Dallas, Texas. The current converter 642 can be arranged with switches 652, 654 that can isolate the voltage-to-current converter 642 from the output and from the digital I / O circuit 610, which is in an off state (i.e., an open circuit or high impedance state), or that enable the voltage-to-current converter 642 to receive an analog signal from the isolated communications controller 310 and output an analog current signal to the first output interconnect 632 (P2).

[0074] According to some implementations, first switch 652 may be a double-throw switch. In a first position (set or cleared by a signal on interconnect AMODE), first switch 652 may connect an interconnect carrying a digital output (DAOUT) from the isolated communications controller to be converted to an analog signal to the input of voltage-to-current converter 642. In a second position, first switch 652 may connect first output interconnect 632 (P2) to the input of voltage-to-current converter 642 to transmit a signal received via P2 to a component of machine 350.

[0075] The third switch 656 can be used, for example, to provide a current path to ground (such as a low impedance path via resistor R30) when receiving an analog signal from a component, or to provide a reference voltage (e.g., ground) when sending an analog signal to a component. The third switch is programmable, for example, by a programming voltage held on the interconnect (labeled GNDEN). The fourth switch 658 can also be used to provide a current path to ground when receiving an analog signal from a component. The programming voltage can be provided as, but is not limited to, a programming voltage signal, a programming current signal, or a programming light signal.

[0076] The configuration of the four switches 652, 654, 656, 658 for transmitting and receiving various types of analog signals will be apparent to those skilled in the art of digital and analog electronics from the foregoing description. For transmitting and receiving digital signals, the first switch 652, the second switch 654, and the fourth switch 658 may be placed in an OFF (open circuit or high impedance) state. For differential digital transmission and reception, the third switch 656 may be placed in an OFF state. For single-ended digital transmission and reception and single-ended analog transmission, the third switch 656 may be placed in an ON (short circuit or low impedance) state. The four switches 652, 654, 656, 658 are programmable by programming voltages held on interconnects connected to the switches (labeled AMODE, AOUTEN, GNDEN, and REFEN, respectively).

[0077] FIG. 6B illustrates another possible implementation of programmable analog I / O circuit 612. The implementation of FIG. 6B is similar to the implementation of FIG. 5A, except that receive signal driver 541 is not switchable. Instead, receive signal driver 541 has an operational amplifier 542 configured as a follower. The operational amplifier 542 in receive signal drivers 540, 541 can condition signals from a wide range of output impedances. In the implementation of FIG. 6B, the second input of multiplexer 512 connects to output interconnect P2 through a resistive path (R14) and to a shunt resistive branch (R16 and T1) that can provide a path for current to ground when T1 is conducting. The circuit of FIG. 6B requires one less chip than the circuit of FIG. 5A and can be used when differential analog signal reception is not required.

[0078] While the above circuitry is described primarily for providing positive power (e.g., positive potential to ground), one skilled in the art of electronics can readily configure the circuitry from the above description to operate at negative voltages or within a range of positive and negative voltages. While the majority of information signaling involves positive potentials in many applications, some analog signals (e.g., from sensors) may involve negative voltages. In such cases, signal level shifting may be used, and a negative potential power supply may be added to the analog I / O circuitry (e.g., to power analog output signal driver 520 and / or receiving signal driver 540), thereby enabling signals from positive to negative voltage values ​​to be transmitted and received. In such cases, programmable signal routing / isolation circuit 430 may be modified to handle positive and negative voltage swings.

[0079] The programmable interface module 315, comprised of the programmable interface circuits 440 described above, may have two output interconnects 452, 454 (ADIO, DIFF) for each interface circuit 440, according to some implementations. In some cases, four interface circuits 440 may be included within the interface module 315. Thus, there may be eight output interconnects from the interface module that may be used to interface with four components of a machine. In such cases, an eight-wire or ten-wire Ethernet cable with the connectors described above may be used to connect the interface module 315 to a breakout box 318 located near the components, as shown in FIG. 3 . The breakout box 318 may receive the Ethernet cable and route separate wires or cables 14 to each component. In other implementations, there may be more or fewer interface circuits 440 within the interface module 315, and different cables and connectors may be used as needed.

[0080] In some implementations, power (e.g., +V DC1 , +VDC2 , -V DC1 ) and / or a reference potential (e.g., ground). In some such cases, cables and connectors with additional wires and pins (e.g., 10-wire instead of 8-wire) may be used. In other such cases, some of the second output interconnects 454 of the interface circuit 440 may not be used and / or may not be associated with a reference potential. For example, one or more of the second output interconnects 454 may be grounded if it is known that they will be used with single-ended signaling only. Alternatively, if the single-ended digital I / O circuit 580 of FIG. 5E is used, the second output interconnects 454(DIFF) may not be present, thereby freeing up one or more wires of an 8-wire Ethernet cable to provide power (+V DC ) and / or reference potential (ground).

[0081] The number of interface circuits 440 used in the programmable interface module 315 determines, at least in part, the number of wires and pins required for the cable and connector interconnects. The pin assignment connectors may be arranged in any suitable manner. For example, an interface module 315 having only four programmable interface circuits 440 may use an 8-pin connector and a standard 8-wire Ethernet cable. If the voltage supply and reference voltage are provided through the cable, the pin assignment may be as shown in Table 1. In this example, two of the interface circuits 440 may include the single-ended digital I / O circuit 580 of FIG. 5E and two include the digital I / O circuit 420 of FIG. 5B. Other implementations may use different pin assignments. In some implementations, the pin assignments may be standardized and recognized as an industry standard.

[0082] [Table 1]

[0083] The disclosed circuitry can convert isolated digital signals to and from the high-speed networked isolated communications controller 310 into the currents and voltages necessary to transmit and / or receive signals from peripheral devices, which may implement a wide variety of signaling schemes (e.g., single-ended, differential, current-mode, digital, analog) in standard or custom voltage and current ranges. The signaling type and voltage or current levels can be user-selectable and programmable by the isolated communications controller 310 via the interconnect 401. Programmability can be implemented in hardware (e.g., as user-configurable switches) in some implementations, in software in some implementations, or through a combination of hardware and software configuration. Software programmability can be implemented as pull-down menus providing per-channel selection of signaling type, data direction, voltage levels, current levels, etc. The software can be part of the software operating the central controller 301 and one or more isolated communications controllers 310 communicating with the central controller.

[0084] In some implementations, the disclosed circuitry may be packaged in a compact, IP67 or similarly durable case that can be distributed throughout a machine. In some implementations, less durable cases may also be used. The packaged case may include the isolated communications controller 310 and the programmable interface module 315, according to some implementations. In other implementations, the packaged case may include only the programmable interface module 315. Distributing such packaged cases throughout a machine can significantly reduce or eliminate custom wiring harnesses, long cables, and electrical cabinets for machine control. For example, the number of Ethernet cables (e.g., waterproof, industry-standard Ethernet cables) used to interconnect machines can be reduced by more than 16 times using the isolated communications controller 310 and programmable interface module 315 of this implementation compared to traditional interconnection approaches for complex automated / semi-automated machines.

[0085] There may be various ways to operate components of machine 350 using programmable interface module 315 of this implementation. Operations associated with an example method 700 are illustrated in the flowchart of FIG. 7. An example method 700 of signaling between a controller (such as an isolated communications controller) and one or more components of the machine may include receiving a programming voltage at an interface circuit that programs interface circuit 440 to receive a first type of signal from the controller (operation 705) for transmission to components 320, 330, 340 of machine 350, where the first type of signal may be either an analog signal or a digital signal. Method 700 may further include receiving a first type of signal from the isolated communications controller (e.g., at one of the analog or digital inputs (AOUT, DOUT, DOUTP, DOUTN) of programmable interface circuit 440) (operation 710) and transmitting a first type of output signal to a signal channel (ADIO or ADIO and DIFF) of programmable interface circuit 440 (operation 720). The transmitted signal may be based on the received first type of signal. The method of signaling between a controller and one or more components of a machine may further or alternatively include receiving a second programming voltage to program interface circuit 440 to receive a second type of signal on the signal channel (operation 730), the second type of signal being one of an analog signal and a digital signal, and receiving the second type of signal on the signal channel (operation 740). The method may further include transmitting a second type of signal to the controller (operation 750) based on the received second type of signal. Such a combination of operations may be performed in a conversational operation, where speaking is in a first mode and listening is in a second mode. Alternatively, such a combination of operations may be performed when the signal channel is repurposed in an existing configuration (e.g., after component replacement).Method 700 may include additional operations related to further programming interface circuit 440 to send and receive various types of analog and digital signals (e.g., single-ended digital signals, differential digital signals, single-ended analog signals, differential analog signals, voltage-derived analog signals, current-derived analog signals, etc.).

[0086] In some implementations, signal channels can be reprogrammed during operation to transmit and / or receive different types of analog and digital signals. For example, a time division multiplexing scheme can be implemented with a channel such that during a first period, the signal channel is programmed to transmit a first type of analog signal to a first machine component. During a subsequent second period, the same signal channel can be programmed to transmit a second type of digital signal to a second machine component. A multiplexer (e.g., located in or after the breakout box 318) can be used to route the signals to different components. During a subsequent third period, the same signal channel can be programmed to receive either an analog signal or a digital signal. Such time division multiplexing schemes can enable even more different uses for the signal channels.

[0087] Various configurations of the programmable interface circuitry of the disclosed implementations are possible, examples of such configurations are listed below. (1) A programmable interface circuit (440) for adaptively exchanging signals between an isolated communications controller (310) and components (320, 330, 340) of a machine (350), the programmable interface circuit comprising: a plurality of interconnects (401) for receiving a programming voltage from the isolated communications controller; signal channels (452, 454) for transmitting signals between the programmable interface circuit and the components; programmable analog I / O circuits (410, 610, 612) coupled to the signal channels for receiving a first analog signal from the isolated communications controller; a programmable digital I / O circuit (420, 580) coupled to the signal channels for receiving a first digital signal from the isolated communications controller; and a current detection circuit (530) for detecting an amount of current flowing through the signal channels, the programmable interface circuit being programmable during operation based on at least a first programming voltage applied to the plurality of interconnects to provide a second analog signal to the signal channels based on the first analog signal or to provide a second digital signal to the signal channels based on the first digital signal. (2) The programmable interface circuit of configuration (1), wherein the programmable interface circuit is programmable based on at least a second programming voltage to receive analog signals and digital signals through the signal channel. (3) The programmable interface circuit of configuration (1) or (2), wherein the programmable interface circuit is programmable based on at least a second programming voltage to transmit at least two different analog signals through the signal channel as the second analog signal. (4) The programmable interface circuit according to configuration (3), wherein a third analog signal of the at least two different types of analog signals is a current-derived analog signal. (5) The programmable interface circuit according to any one of the configurations (1) to (4), further comprising at least one amplifier circuit coupled to the signal channel to provide the second analog signal and the second digital signal transmitted by the signal channel with an output current of 4 milliamperes (mA) to 24 mA. (6) A programmable interface circuit according to any one of the configurations (1) to (5), wherein the programmable interface circuit is programmable based on at least a second programming voltage to transmit and receive at least two types of digital signals through the signal channel. (7) A programmable interface circuit according to any one of configurations (1) to (6), wherein the programmable analog I / O circuit includes a first feedback circuit path, a second feedback circuit path, an operational amplifier having a feedback input, and a multiplexer configured to connect the feedback input to either the first feedback circuit path or the second feedback circuit path based on at least a second programming voltage. (8) The programmable interface circuit according to configuration (7), wherein the first feedback circuit path detects the voltage of the signal channel, and the second feedback circuit path detects the amount of current flowing through the signal channel. (9) Programmable analog I / O circuitry a first circuit configured to drive the signal channel to a high logic level; The programmable interface circuit of any one of configurations (1) to (8), further comprising: a second circuit configured to drive the signal channel to a low logic level. (10) The programmable interface circuit of configuration (9), wherein the second circuit includes a switch for isolating a low logic level from the signal channel based on at least a second programming voltage. (11) A programmable interface circuit according to any one of the configurations (1) to (10), wherein the programmable digital I / O circuit comprises a transceiver connected between one or more of the plurality of interconnects and the signal channel. (12) The programmable interface circuit of configuration (11), wherein the transceiver is programmable based on at least a second programming voltage to transmit and receive single-sided signals and differential digital signals. (13) The programmable interface circuit according to any one of the configurations (1) to (12), which is combined with an isolated communication control device that connects to the programmable interface circuit via one or more of a plurality of interconnects. (14) The combination of configuration (13), wherein the isolated communication controller comprises a programmable logic controller or a microcontroller. (15) The combination of (13) or (14), further comprising a component. (16) The combination of configuration (15), wherein the component is at least one of a sensor, a motor or actuator, or an imaging device.

[0088] Further exemplary configurations are listed below. In some implementations, one or more of the sub-aspects (2) to (16) of the configuration (1) may be combined with one or more of the following configurations. (17) A programmable interface circuit (440) for adaptively exchanging signals between an isolated communications controller (310) and components (320, 330, 340) of a machine (350), the programmable interface circuit comprising: a plurality of interconnects (401) for receiving a programming voltage; signal channels (452, 454) for transmitting signals between the programmable interface circuit and the components; a programmable analog I / O circuit (410, 630) having a programmable operational amplifier (522 or 542) coupled to the signal channels to receive a first analog signal from the isolated communications controller; and a programmable digital I / O circuit (420) coupled to the signal channels to receive a first digital signal from the isolated communications controller, the programmable interface circuit being programmable during operation based on at least a first programming voltage applied to the plurality of interconnects to provide a second analog signal to the signal channels based on the first analog signal or to provide a second digital signal to the signal channels based on the first digital signal. (18) The programmable interface circuit of configuration (17), further comprising a switchable output signal driver for receiving the first analog signal within the programmable analog I / O circuit, wherein the feedback signal for the switchable output signal driver is configured to switch from a current detection mode to a voltage detection mode based on at least a second programming voltage. (19) The programmable interface circuit of configuration (18), wherein the switchable output signal driver comprises an operational amplifier. (20) The programmable interface circuit of configuration (18), further comprising a current detection circuit for detecting an amount of current flowing through the signal channel and providing a feedback signal to the switchable output signal driver in a current detection mode. (21) A programmable interface circuit according to any one of the configurations (17) to (20), further comprising a switchable receive signal driver within a programmable analog I / O circuit including an amplifier configured to be switchable between a single-ended amplifier and a differential amplifier. (22) A programmable interface circuit according to any one of configurations (17) to (21), wherein the programmable interface circuit is further programmable based on at least a second programming voltage to receive analog and digital signals through a signal channel. (23) The programmable interface circuit of any one of configurations (17) to (22), wherein the programmable interface circuit is programmable based on at least a second programming voltage to transmit analog signals of at least two different types of signaling through the signal channel. (24) The programmable interface circuit according to any one of the configurations (17) to (23), wherein the programmable interface circuit is programmable based on a programming voltage to transmit and receive at least two types of digital signals through the signal channel. (25) The programmable interface circuit according to any one of the configurations (17) to (24), further comprising a programmable signal path setting / isolation circuit for connecting the programmable analog I / O circuit and the programmable digital I / O circuit to a signal channel. (26) The programmable interface circuit of any one of configurations (17) to (25), wherein the programmable signal routing / isolation circuit comprises a transistor for isolating at least a portion of the programmable digital I / O circuit from the signal channel. (27) The programmable interface circuit according to any one of the configurations (17) to (26), which is combined with an isolated communication control device that connects to the programmable interface circuit via one or more of a plurality of interconnects. (28) The combination of configuration (27), wherein the isolated communication controller comprises a programmable logic controller or a microcontroller. (29) The combination according to (27) or (28), further comprising a component.

[0089] The following configurations can be realized in combination with the aspects of configurations (2) to (16) and (18) to (29). (30) A programmable interface circuit (440) for adaptively exchanging signals between an isolated communications controller (310) and components (320, 330, 340) of a machine (350), the programmable interface circuit comprising: a plurality of interconnects (401) for receiving a programming voltage; signal channels (452, 454) for transmitting signals between the programmable interface circuit and the components; a programmable analog I / O circuit (410, 630) coupled to the signal channels and programmable to receive a first analog signal from the isolated communications controller; and a programmable digital I / O circuit (420) coupled to the signal channels and programmable to receive a first digital signal from the isolated communications controller, the programmable analog I / O circuit comprising: a first feedback circuit path; a second feedback circuit path; an operational amplifier having a feedback input; and a multiplexer for connecting the feedback input to either the first feedback circuit path or the second feedback circuit path based on at least a first programming voltage.

[0090] Various methods of operating a programmable interface circuit of the above listed configurations may be implemented. Examples of such methods are listed below. (31) A method of operating a programmable interface circuit (440), the method comprising: receiving a first programming voltage to program (705) the interface circuit to receive a first signal from an isolated communications controller (310) to be transmitted to a component (320, 325, 330, 340) of a machine (350), the first signal being either an analog signal or a digital signal; receiving (710) the first signal from the isolated communications controller and transmitting (720) a first output signal based on the received first signal to a signal channel of the programmable interface circuit, the first output signal being the same type of signal as the received first signal; receiving a second programming voltage to program (730) the interface circuit to receive a second signal from the component on the signal channel, the second signal being a different type of signal than the first signal; receiving (740) the second signal on the signal channel; and transmitting (750) a first input signal based on the received second signal to the isolated communications controller. (32) The method according to (31), wherein the first signal is a differential analog signal. (33) The method according to (31) or (32), wherein the first signal is an analog signal derived from a current having an amplitude of 4 mA to 24 mA. (34) The method according to any one of (31) to (33), wherein the first signal is a differential digital signal. (35) The method according to any one of (31) to (34), wherein the first signal is a low-voltage differential digital signal. (36) A method according to any one of (31) to (36), wherein the second signal is a standardized network communication signal requiring two or four signal transmission wirings. (37) The method according to any one of (31) to (37), wherein the second signal is a differential analog signal. (38) The method according to any one of (31) to (38), wherein the second signal is an analog signal derived from a current having an amplitude of 4 mA to 24 mA. (39) The method according to any one of (31) to (39), wherein the second signal is a differential digital signal. (40) The method according to any one of (31) to (40), wherein the second signal is a low-voltage differential digital signal. (41) The method according to any one of (31) to (41), wherein the first signal is an analog signal derived from a current, and the second signal is an analog signal derived from a voltage. (42) A method according to any one of (31) to (42), wherein transmitting the first output signal includes selecting a feedback circuit for an operational amplifier in the programmable interface circuit based at least on a first programming voltage. (43) A method according to any one of (31) to (43), wherein receiving the second signal includes selecting a single-ended amplification mode or a differential amplification mode for an operational amplifier in the programmable interface circuit based on at least a second programming voltage. (44) A method according to any one of (31) to (44), wherein transmitting the first input signal to the isolated communication control device includes electrically isolating at least a portion of the programmable digital I / O circuit from the signal channel. (45) A method according to any one of (31) to (45), wherein transmitting the first input signal to the isolated communication control device includes electrically isolating at least a portion of the programmable analog I / O circuit from the signal channel.

[0091] While various implementations of the present invention have been described and illustrated herein, those skilled in the art will readily conceive of various other means and / or structures for performing the functions described herein and / or obtaining one or more of the results and / or advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the implementations of the present invention described herein. More broadly, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and that the actual parameters, dimensions, materials, and / or configurations will depend on the specific application for which the teachings of the present invention are used. Those skilled in the art will recognize, or be able to identify, using no more than routine experimentation, numerous equivalents to the specific implementations of the present invention described herein. Therefore, it should be understood that the foregoing implementations are presented by way of example only, and that, within the scope of the appended claims and their equivalents, implementations of the present disclosure are directed to each individual feature, system, article, material, and / or method described herein. In addition, any combination of two or more of such features, systems, articles, materials, and / or methods, if not mutually inconsistent, is within the scope of the present disclosure.

[0092] The above implementations can be realized in any of numerous ways. For example, the implementations can be realized using hardware, software, or a combination thereof. If implemented in software, the software code can be executed on any suitable processor or group of processors, whether provided on a single computer or distributed across multiple computers.

[0093] Additionally, various concepts of the present invention may be embodied as one or more methods, examples of which are provided. The actions performed as part of a method may be ordered in any suitable manner. As a result, implementations may be configured to perform actions in an order different from that shown, which may include performing some actions simultaneously even though they are shown as sequential actions in the example implementations.

[0094] All definitions provided and used herein should be understood to control dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0095] As used in this specification and the claims, the indefinite articles "a" and "an" should be understood to mean "at least one," unless expressly indicated otherwise.

[0096] As used in this specification and in the claims, the phrase "and / or" should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are present conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements, whether related or unrelated to the elements specifically identified, may optionally be present other than the elements expressly identified in the "and / or" clause. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may in one implementation refer only to A (optionally including elements other than B), while in another implementation it may refer only to B (optionally including elements other than A), while in yet another implementation it may refer to both A and B (optionally including other elements), and so on.

[0097] As used in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be understood to be inclusive, i.e., the inclusion of at least one of a number or list of elements, but also including more than one, and optionally including additional unlisted items. Only terms expressly indicated otherwise, such as "only one of," "exactly one of," or, when used in the claims, "consisting of," refer to the inclusion of exactly one of a number or list of elements. Generally, as used herein, the term "or" should only be construed to indicate exclusive alternatives (i.e., "one or the other, but not both") when preceded by exclusive terms such as "either," "one of," "only one of," or "exactly one of." When used in the claims, "consisting essentially of" shall have its ordinary meaning as used in the field of patent law.

[0098] As used in this specification and claims, the phrase "at least one" in connection with a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each and every element specifically listed in the list of elements, nor does it exclude any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than the specifically identified element to which the phrase "at least one" refers in a list of elements, whether related or unrelated to the specifically identified element. Thus, as a non-limiting example, "at least one of A and B" (or, in other words, "at least one of A or B," or, in other words, "at least one of A and / or B") can refer in one implementation to at least one A, optionally including more than one A, and no B (and optionally including elements other than B); in another implementation to at least one B, optionally including more than one B, and no A (and optionally including elements other than A); in yet another implementation to at least one A, optionally including more than one A, and at least one B, optionally including more than one B (and optionally including other elements); and so on.

[0099] In the claims and the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like, should be understood to be open-ended, i.e., to mean including, but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed and semi-closed transitional phrases, respectively, as set forth in the United States Patent and Trademark Office Manual of Patent Examining Procedures, Section 2111.03.

[0100] The terms "about," "approximately," and "substantially" may be used to refer to values ​​(such as target values ​​used within a numerical range) and are intended to encompass the stated value plus or minus variations that would be considered within the scope of the implementation of the present invention. In some implementations, the amount of variation may be on the order of ±5% of the recited value, in some implementations on the order of ±10% of the recited value, and in some implementations on the order of ±20% of the recited value. The term "essentially" is used to refer to a value that varies by no more than ±3%.

Claims

1. a programmable interface circuit for adaptively exchanging signals between a controller and machine components, comprising: a plurality of interconnects for receiving a plurality of programming inputs; a signal channel for transmitting signals between the programmable interface circuit and the component; a programmable analog I / O circuit coupled to the signal channel and programmable to receive a first analog signal from the controller; a first feedback circuit path; a second feedback circuit path; an operational amplifier having a feedback input; a multiplexer for connecting the feedback input to the first feedback circuit path or the second feedback circuit path based on at least a first programming input of the plurality of programming inputs; a programmable digital I / O circuit coupled to the signal channel and programmable to receive a first digital signal from the controller; A programmable interface circuit comprising:

2. A programmable interface circuit for adaptively exchanging signals between a control device and a machine component, comprising: a plurality of interconnects for receiving a plurality of programming inputs; a signal channel for transmitting signals between the programmable interface circuit and the component; a programmable analog I / O circuit coupled to the signal channel and programmable to receive a first analog signal from the controller; a first feedback circuit path; a second feedback circuit path; an operational amplifier having a feedback input and an output to the signal channel; a multiplexer for connecting the feedback input to the first feedback circuit path or the second feedback circuit path based on at least a first programming input of the plurality of programming inputs; a programmable digital I / O circuit coupled to the signal channel and programmable to receive a first digital signal from the controller; A programmable interface circuit comprising:

3. A method for operating the programmable interface circuit of claim 1, comprising: receiving a first programming input from the plurality of programming inputs that programs the programmable interface circuit to receive a first signal from the controller to be transmitted to the component of the machine, the first signal being either the first analog signal or the first digital signal; receiving the first signal from the controller; transmitting a first output signal based on the received first signal to a signal channel of the programmable interface circuit, the first output signal being the same type of signal as the received first signal; receiving a second programming input from the plurality of programming inputs for programming the programmable interface circuit to receive a second signal from the component on the signal channel, the second signal being a different type of signal than the first signal; receiving the second signal on the signaling channel; transmitting a first input signal to the controller based on the received second signal.

4. The first signal is differential analog signals, a current-derived analog signal having an amplitude between 4 mA and 24 mA; differential digital signals, and Low-Voltage Differential Digital Signals The method of claim 3, wherein the method is one of:

5. The second signal is Standardized network communication signals requiring two or four signal transmission wires; differential analog signals, a current-derived analog signal having an amplitude between 4 mA and 24 mA; differential digital signals, and Low-Voltage Differential Digital Signals The method of claim 3, wherein the method is one of:

6. The method of claim 3 , wherein the first signal is a current-derived analog signal and the second signal is a voltage-derived analog signal.

7. 4. The method of claim 3, wherein transmitting the first output signal comprises selecting a feedback circuit for an operational amplifier in the programmable interface circuit based at least on the first programming input.

8. 4. The method of claim 3, wherein receiving the second signal includes selecting a single-ended amplification mode or a differential amplification mode for an operational amplifier in the programmable interface circuit based on at least the second programming input.

9. 4. The method of claim 3, wherein transmitting the first input signal to the controller comprises transmitting the first input signal to an isolated communications controller that electrically isolates at least a portion of a programmable digital I / O circuit or at least a portion of a programmable analog I / O circuit from the signal channel.

10. The programmable interface circuit, following receipt of at least a first programming input from the controller, receiving a first digital signal from the controller and providing a second digital signal having a first digital signal type to the signal channel based on the first digital signal; or and programmable in a digital mode to at least one of receive a third digital signal having the first digital signal type from the component of the machine via the signal channel and provide a fourth digital signal to the controller based on the third digital signal; the programmable interface circuit, following receipt of at least a second programming input from the controller, receiving a fifth digital signal from the controller and, based on the fifth digital signal, providing a sixth digital signal to the signal channel having a second digital signal type different from the first digital signal type; or receiving a seventh digital signal having the second digital signal type from the component of the machine via the signal channel; and providing an eighth digital signal to the controller based on the seventh digital signal; the programmable interface circuit, following receipt of at least a third programming input from the controller, receiving a first analog signal or a ninth digital signal from the controller, and providing a second analog signal having a first analog signal type to the signal channel based on the first analog signal or the ninth digital signal; or and reprogrammable in an analog mode to at least one of receive a third analog signal having the first analog signal type from the component of the machine via the signal channel and provide a fourth analog signal or a tenth digital signal to the controller based on the third analog signal; the programmable interface circuit, following receipt of at least a fourth programming input from the controller, receiving a fifth analog signal or an eleventh digital signal from the control device, and providing a sixth analog signal to the signal channel based on the fifth analog signal or the eleventh digital signal, the sixth analog signal having a second analog signal type different from the first analog signal type; or 3. The programmable interface circuit of claim 1, wherein the programmable interface circuit is reprogrammable in the analog mode to at least one of receive a seventh analog signal having the second analog signal type from the component of the machine via the signal channel and provide an eighth analog signal or a twelfth digital signal to the controller based on the seventh analog signal.

11. 3. The programmable interface circuit of claim 1, in combination with an isolated communication controller connected between the controller and the programmable interface circuit.

12. 12. The programmable interface circuit of claim 11, wherein the isolated communications controller is configured to receive a serial signal from the controller and output at least two parallel signals to the plurality of interconnects.

13. the first digital signal type is a single-ended digital signal type and the second digital signal type is a differential digital signal type; or 11. The programmable interface circuit of claim 10, wherein the first digital signal type is one of RS-485, Profibus, or CAN bus, and the second digital signal type is another one of RS-485, Profibus, or CAN bus.

14. 11. The programmable interface circuit of claim 10, wherein the first analog signal type comprises a digital current modulation superimposed on a bias current.

15. 11. The programmable interface circuit of claim 10, wherein the first analog signal type is a single-ended analog signal type and the second analog signal type is a differential analog signal type.

16. a transceiver coupled to a first portion of the plurality of interconnects and coupled to the signal channel, the transceiver operable in the digital mode to receive at least the first digital signal and to receive at least the third digital signal; the operational amplifier having an input terminal coupled to a first interconnect of the plurality of interconnects and having an output terminal; a transistor coupled to the signal channel and having a control terminal coupled to the output terminal of the operational amplifier; 11. The programmable interface circuit of claim 10, wherein the operational amplifier is operable in the analog mode to receive at least the first analog signal and at least the third analog signal.

17. 17. The programmable interface circuit of claim 16, further comprising an adjustable high level logic driver circuit coupled to at least one of the plurality of interconnects to convert a first high logic level of the first digital signal to a second high logic level for the second digital signal, the second high logic level being different from the first high logic level.

18. The programmable interface circuit of claim 16, further comprising a current detection circuit coupled to the signal channel, wherein the operational amplifier is configured to receive a feedback signal from the current detection circuit at the feedback input of the operational amplifier to control the amount of current supplied to the signal channel in the analog mode and in the digital mode.

19. The programmable interface circuit of claim 18, further comprising a second operational amplifier connected to the signal channel and having two input terminals configured to differentially detect a voltage between a first conductive interconnect (ADIO) and a second conductive interconnect (DIFF) of the signal channel.

20. 17. A programmable interface circuit as claimed in claim 16 in combination with the controller.

21. The programmable interface circuit, following receipt of at least a first programming input from the control device, receiving a first digital signal from the controller and providing a second digital signal having a first digital signal type to the signal channel based on the first digital signal; or receiving a third digital signal having the first digital signal type from the component of the machine via the signal channel; and providing a fourth digital signal to the controller based on the third digital signal; the programmable interface circuit, following receipt of at least a second programming input from the controller, receiving a fifth digital signal from the controller and, based on the fifth digital signal, providing a sixth digital signal to the signal channel having a second digital signal type different from the first digital signal type; or 3. The programmable interface circuit of claim 1, wherein the programmable interface circuit is reprogrammable to at least one of receive a seventh digital signal having the second digital signal type from the component of the machine via the signal channel and provide an eighth digital signal to the controller based on the seventh digital signal.

22. 22. The programmable interface circuit of claim 21 in combination with an isolated communications controller connected between the controller and the programmable interface circuit.

23. the first digital signal type is a single-ended digital signal type and the second digital signal type is a differential digital signal type; or 22. The programmable interface circuit of claim 21, wherein the first digital signal type is one of RS-485, Profibus, or CAN bus, and the second digital signal type is another one of RS-485, Profibus, or CAN bus.

24. a transceiver coupled to a first portion of the plurality of interconnects and coupled to the signal channel, the transceiver operable to receive at least the first digital signal and to receive at least the third digital signal; the operational amplifier having a first input terminal coupled to a first interconnect of the plurality of interconnects and having an output terminal; 22. The programmable interface circuit of claim 21, further comprising: a transistor coupled to the signal channel and having a control terminal coupled to the output terminal of the operational amplifier.

25. 25. The programmable interface circuit of claim 24, further comprising an adjustable high level logic driver circuit coupled to at least a second interconnect of the plurality of interconnects to convert a first high logic level of the first digital signal to a second high logic level for the second digital signal, the second high logic level being different from the first high logic level.

26. The programmable interface circuit of claim 24, further comprising a current detection circuit coupled to the signal channel, wherein the operational amplifier is configured to receive a feedback signal from the current detection circuit to control the amount of current supplied to the signal channel.

27. 25. A programmable interface circuit as claimed in claim 24 in combination with the controller.

28. The programmable interface circuit, following receipt of at least a first programming input from the controller, receiving a first analog signal or a first digital signal from the controller and providing a second analog signal having a first analog signal type to the signal channel based on the first analog signal or the first digital signal; or receiving a third analog signal having the first analog signal type from the component of the machine via the signal channel, and providing a fourth analog signal or a second digital signal to the controller based on the third analog signal; the programmable interface circuit, upon receiving at least a fourth control input from the controller, receiving a fifth analog signal or a third digital signal from the control device, and providing a sixth analog signal to the signal channel based on the fifth analog signal or the third digital signal, the sixth analog signal having a second analog signal type different from the first analog signal type; or 3. The programmable interface circuit of claim 1, wherein the programmable interface circuit is reprogrammable to at least one of receive a seventh analog signal having the second analog signal type from the component of the machine via the signal channel and provide an eighth analog signal or a fourth digital signal to the controller based on the seventh analog signal.

29. 30. The programmable interface circuit of claim 28 in combination with an isolated communications controller connected between the controller and the programmable interface circuit.

30. 30. The programmable interface circuit of claim 28, wherein the first analog signal type is a single-ended analog signal type and the second analog signal type is a differential analog signal type.

31. 30. The programmable interface circuit of claim 28, wherein the first analog signal type comprises a digital current modulation superimposed on a constant current.

32. the operational amplifier having a first input terminal coupled to a first interconnect of the plurality of interconnects and having an output terminal; a transistor coupled to the signal channel and having a control terminal coupled to the output terminal of the operational amplifier; 30. The programmable interface circuit of claim 28, wherein the operational amplifier is operable to receive at least the first analog signal and at least the third analog signal.

33. A current detection circuit coupled to the signal channel, the operational amplifier being arranged to receive a feedback signal from the current detection circuit at the feedback input to the operational amplifier to control the amount of current supplied to the signal channel; and 33. The programmable interface circuit of claim 32, further comprising: a second operational amplifier having two inputs connected to the signal channel and configured to differentially sense a voltage between a first conductive interconnect (ADIO) and a second conductive interconnect (DIFF) of the signal channel.

34. 33. A programmable interface circuit as claimed in claim 32 in combination with the controller.

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