Redundant Input Module Resistance Control During Module Disconnect
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Solution Overview
Problem
High availability systems with redundant monitoring in industrial automation face challenges in maintaining expected electrical conditions when one of the redundant components becomes unavailable, particularly in ensuring consistent line impedance for communication circuits, which can lead to system downtime and component degradation.
Innovation Solution
The system employs a terminal base with input modules that include resistors in series, with switches controlling the line impedance, allowing automatic adjustment and redundancy to maintain expected electrical conditions, ensuring continuous operation even when one input module is disconnected, without requiring additional field wiring or easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant input modules are used in high availability systems, then system reliability is improved, but maintaining expected electrical conditions (line impedance) becomes difficult when one module becomes unavailable
Solution Approach 1:
The patent implements dynamic impedance adjustment by detecting whether a redundant input module is connected and automatically adjusting the impedance of the active module accordingly. When both modules are connected, each presents a higher impedance; when one is removed, the remaining module adjusts to provide the expected line impedance, thus dynamically adapting to system configuration changes while maintaining electrical compatibility with communication devices
Solution Approach 2:
The patent changes the electrical impedance parameter of the input module based on the connection status of redundant modules. By detecting the absence of a redundant module and adjusting the impedance value accordingly, the system maintains the expected electrical conditions for communication devices without requiring manual reconfiguration or additional wiring
2Device complexity
If manual reconfiguration is required when replacing redundant components, then system complexity is reduced, but system downtime increases
Solution Approach 1:
The patent implements self-service by automatically detecting when a redundant input module is removed or replaced and autonomously adjusting the impedance configuration without requiring manual intervention. The system monitors its own state and performs the necessary reconfiguration automatically, eliminating the need for technicians to manually adjust settings during component replacement
Solution Approach 2:
The patent uses feedback mechanisms to monitor the connection status of redundant input modules and automatically triggers impedance adjustment based on detected changes. The system continuously monitors whether redundant modules are connected and uses this feedback information to dynamically adjust electrical parameters, ensuring continuous operation during maintenance activities
3Stability of the object's composition
If additional field wiring is implemented to maintain impedance, then line impedance stability is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent extracts the impedance maintenance function from the physical wiring structure and implements it through electronic control. Instead of using additional field wiring or external impedance-matching components, the system uses integrated circuitry within the input modules to dynamically adjust and maintain the required line impedance, eliminating the need for complex additional wiring
Data Source
AI summary
An input module may include a first resistor and a second resistor coupled in series with the first resistor. The input module may also include a switch that may electrically isolate the second resistor based on a voltage output by an additional input module electrically coupled to the input module via a terminal base.