Configurable I/O Module Reduces Wiring Complexity
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Solution Overview
Problem
Existing control systems, particularly complex and distributed ones, face challenges in coordinating actions across various components due to the use of fixed-configuration I/O modules, which require custom wiring and multiple power supplies, leading to complex and error-prone connections.
Innovation Solution
A configurable, connectorized I/O module that simplifies wiring by using a software configuration method to electrically configure the module, reducing the need for custom wiring and external components, and provides device-level software for closed-loop control, enabling direct connections between sensors and actuators with a single part number, and allows for secure connections to a server for supervisory control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-configuration I/O modules are used, then specific sensing and actuation functions are achieved, but wiring complexity and number of components increase
Solution Approach 1:
The patent implements a universal I/O module that can be configured to perform multiple different sensing and actuation functions through software programming. A single module type replaces multiple specialized modules, and the module can adapt its electrical configuration (voltage levels, current sourcing/sinking, connector assignments) via software to match various sensor and actuator requirements, thereby reducing wiring complexity and component count while maintaining functional versatility
Solution Approach 2:
The I/O module employs dynamic reconfiguration capabilities where the electrical configuration of connectors and pins can be changed at runtime through software. The module can dynamically adjust voltage levels, switch between sourcing and sinking modes, and reassign connector functions without physical rewiring, allowing the system to adapt to different operational requirements while maintaining a simplified fixed wiring structure
2Adaptability or versatility
If multiple power supplies are used for different I/O modules, then various voltage requirements are met, but system complexity and component count increase
Solution Approach 1:
The patent consolidates multiple power supply functions into a single centralized power supply unit. The unified power supply can output multiple voltage levels (5V, 3.3V, 12V, 24V) and serves all I/O modules through a common power distribution network. This eliminates the need for separate power supplies at each module, reducing component count while maintaining the ability to meet diverse voltage requirements through software-controlled power management
3Adaptability or versatility
If custom wiring is used for each I/O module, then specific connection requirements are satisfied, but error rate and installation complexity increase
Solution Approach 1:
The system performs preliminary configuration of I/O module connections through software before physical installation or operation. Connector assignments, pin configurations, and wiring mappings are pre-defined and stored in the module's memory. During installation, modules are connected using standardized wiring patterns without requiring custom wire-by-wire configuration, and the software automatically applies the pre-configured connection parameters, thereby eliminating wiring errors while maintaining connection flexibility
Solution Approach 2:
The patent uses software-based connection configurations that can be copied and replicated across multiple I/O modules. Once a wiring configuration is established for one module, it can be duplicated to other modules with identical requirements, ensuring consistency and reducing errors. The software stores connection templates that can be instantiated across the system without requiring physical rewiring variations
Data Source
AI summary
A configurable, connectorized system for providing supervisory and distributed control dramatically reduces the number of wire connections that must be made to connect sensors and actuators to a control system, reducing the number of different control hardware components required to connect one or more sensors and actuators through use of a configurable I/O module.