I/O Module Locking Actuator Position Sensor
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Solution Overview
Problem
Traditional automation control systems face inefficiencies in coupling, locking, and uncoupling I/O modules from bases, particularly in detecting the position of locking actuators to manage power modes and redundancy in electrical components.
Innovation Solution
Incorporating a sensor system that detects the position of a locking actuator using a coil and metallic component, generating a signal indicative of the actuator's position to initiate power mode changes and inform redundant components of impending removal, thereby enhancing the efficiency of electrical component interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional friction or simple locking mechanisms are used to secure I/O modules to bases, then the coupling mechanism is simple and easy to manufacture, but the ability to detect locking position and manage power modes efficiently is insufficient
Solution Approach 1:
The patent replaces traditional mechanical locking detection methods with an inductive sensing system. A sensor detects the position of a metallic component on the locking actuator through electromagnetic induction, eliminating the need for complex mechanical position detection mechanisms while enabling precise locking position detection.
Solution Approach 2:
The patent introduces a metallic component as an intermediary element on the locking actuator that mediates between the mechanical locking mechanism and the electronic sensor. This metallic component interacts with the inductive sensor to transmit locking position information without requiring direct mechanical contact or complex mechanical sensing mechanisms.
2Reliability
If locking actuators are used to secure electrical components, then the coupling is secure and reliable, but the system cannot efficiently detect actuator position to manage power modes and redundancy
Solution Approach 1:
The patent implements a feedback mechanism where the sensor continuously detects the position of the locking actuator through the metallic component and provides this information to the control system. This feedback enables the system to monitor coupling status, manage power modes appropriately, and handle redundancy configurations based on real-time actuator position information.
Solution Approach 2:
The patent replaces mechanical position indication methods with electromagnetic induction sensing. The inductive sensor detects the position of the metallic component on the locking actuator without mechanical contact, providing reliable position information while maintaining coupling reliability through the intact mechanical locking mechanism.
3Use of energy by moving object
If traditional power management without position sensing is used, then the system is simpler, but power efficiency is reduced due to inability to switch from startup mode to switching mode
Solution Approach 1:
The sensor provides feedback on locking actuator position to the power management system, enabling automatic switching between startup mode and switching mode based on detected coupling status. This feedback-driven power management improves energy efficiency by transitioning to more efficient operating modes once components are securely coupled.
Solution Approach 2:
The patent uses electromagnetic induction to detect locking position, replacing complex mechanical position sensing mechanisms. This substitution enables efficient power management through electronic control while keeping the overall system complexity manageable by leveraging standard inductive sensing technology.
4Reliability
If redundant electrical components are used for system reliability, then system reliability improves, but the system cannot efficiently manage redundancy without position detection capability
Solution Approach 1:
The sensor provides real-time feedback on the coupling status of redundant electrical components through detection of locking actuator positions. This information enables the control system to automatically manage redundancy configurations, determine which components are active or standby, and facilitate seamless failover operations, greatly simplifying redundancy management.
Solution Approach 2:
The patent uses non-contact inductive sensing to detect the position of locking actuators on redundant components, replacing complex mechanical position detection systems. This substitution enables efficient electronic management of redundant components while maintaining system reliability through accurate coupling status detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution improves the efficiency of power management and redundancy handling in automation control systems by accurately sensing locking actuator positions, enabling more efficient power usage and seamless component interactions.
Implementation Method 1
The sensor can include a coil supported by the second electrical component and a metallic component supported by the shaft. The metallic component can be spaced apart from the coil a greater distance when the locking actuator is in the first position than when the locking actuator is in the second position whereby a change in the inductance of the coil corresponds to the signal indicative of the position of the locking actuator.
Data Source
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AI summary
An I/O system including an I/O base, and at least one I/O module mechanically and electrically coupled with the I/O base. The I/O module includes a locking actuator assembly having a locking actuator movable from a first unlocked position to a second locked position, the locking actuator configured to interlock with the I/O base to secure the I/O module to the base when in the second position, and a sensor for sensing a position of the locking actuator and generating a signal indicative of the position of the locking actuator.