Modular Block I/O Connections for Reconfigurable Automation Modules
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Solution Overview
Problem
Existing industrial automation block I/O modules are not easily customizable or reconfigurable for specific applications, leading to inefficiencies and increased downtime due to the need for multiple modules with unused connections and complex wiring arrangements.
Innovation Solution
A modular block I/O module with self-contained I/O segments and sockets allows for customizable and reconfigurable connections, enabling flexible deployment and reconfiguration without disconnecting network or power connections, and simplifying installation and maintenance by housing connectors on the sides or bottom rather than the front.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If block I/O modules are made self-contained with permanent I/O circuits in a single housing, then reliability and ease of deployment are improved, but adaptability and reconfigurability deteriorate
Solution Approach 1:
The I/O module is divided into a base unit and removable I/O segments. The base unit contains permanent components (power supply, network adapter, processors), while I/O segments are separate, interchangeable modules that can be attached or detached to reconfigure the system's input/output capabilities without affecting the core functionality.
Solution Approach 2:
The system transitions from a static, fixed configuration to a dynamic, reconfigurable architecture. The removable I/O segments allow the system to adapt its configuration based on application requirements, enabling hot-swapping and reconfiguration without system downtime or disconnection of network/power connections.
2Adaptability or versatility
If multiple different block I/O modules are deployed to meet specific application requirements, then adaptability is improved, but device complexity and wiring complexity increase
Solution Approach 1:
A single base unit is designed to support multiple different I/O segment types through universal interfaces (sockets and connectors). This allows one base unit to perform multiple functions by simply changing the attached I/O segment, eliminating the need for multiple specialized modules and reducing wiring complexity.
3Ease of operation
If connectors are located on the front face of the block I/O module, then ease of connection is improved, but space utilization and accessibility for indicators deteriorate
Solution Approach 1:
The connector location is moved from the front face (two-dimensional surface) to the side or bottom of the module (different spatial dimension). This relocates connection points to areas that do not compete with the front face space required for indicators, LEDs, and user interaction elements, effectively resolving the spatial conflict through dimensional redistribution.
Data Source
Figure 1~1A
Figure 2
Figure 3A
AI summary
An industrial automation input/output module includes a housing, a power supply, and a network adapter. A plurality of I/O sockets are located in the housing, each comprising an socket contacts for power and data. A plurality of I/O segments are located in the housing, and each includes a segment housing that contains an I/O circuit for processing data associated with a controlled system and for communicating said data between to/from the network adapter. Each I/O segment further includes segment power/data contacts connected to the I/O circuit. Each I/O segment is received in one of the I/O sockets such that the segment contacts operably mate with the socket contacts for transmission of power and data and power between the socket contacts and the segment contacts. A plurality of field connectors are connected to the module housing and adapted for operably connecting with the associated controlled system.