Compact Modular Card System for Power Controller
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Solution Overview
Problem
Current panel-mounted controller designs are limited in the number and size of circuit boards and terminals that can be incorporated within a given package size, hindering the increase in features and functionality.
Innovation Solution
The design incorporates a 1/16 DIN power controller with a housing that accommodates multiple circuit boards, including a power supply circuit board and communications circuit boards with various protocols like Ethernet/IP, Modbus TCP, RS-232, and RS-485, allowing for efficient use of space with modular configurations and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple circuit boards and terminals are incorporated to increase features and functionality, then the device complexity and component count increase, but the available space within a given package size is limited
Solution Approach 1:
The controller is divided into multiple separate circuit boards (power supply circuit board, communications circuit board, control circuit board) that can be independently designed, manufactured, and configured. Each board handles specific functions, allowing the system to achieve high versatility through modular composition rather than integrating all functions into a single complex board.
Solution Approach 2:
The housing and circuit board carrier are designed as universal platforms that can accommodate different types and configurations of circuit boards. The system supports multiple communication protocols (Ethernet/IP, Modbus TCP, RS-232, RS-485) and can be configured for various applications through selective board placement and orientation, making the same physical platform adaptable to diverse functional requirements.
2Area of stationary object
If circuit boards are arranged to maximize surface area and terminal usage, then space utilization improves, but the layout complexity and manufacturing difficulty increase
Solution Approach 1:
The circuit boards are arranged in a three-dimensional configuration within the housing, utilizing vertical space and multiple levels rather than only horizontal plane arrangement. The carrier system allows boards to be positioned at different heights and orientations, maximizing the use of available volume and surface area while maintaining accessible connection points.
Solution Approach 2:
A circuit board carrier serves as an intermediary component that simplifies the assembly process. The carrier provides standardized mounting positions, alignment features, and connection interfaces, reducing the complexity of directly assembling multiple circuit boards into the housing. This mediator component standardizes the integration process despite the complex spatial arrangement.
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 configuration enables increased features and functionality by maximizing circuit board surface area and terminal usage within a compact package, reducing the number of components needed and enhancing compatibility across different applications.
Implementation Method 1
the communications circuit board defines an open area substantially clear of electronic components to provide dielectric
Data Source
AI summary
A 1/16 DIN power controller configuration is provided that includes a housing, a circuit board carrier disposed within the housing and capable of engaging at least three circuit boards within the housing, a power supply circuit board disposed within the housing and engaged by the circuit board carrier, and a communications circuit board disposed adjacent the power supply circuit board within the housing and engaged by the circuit board carrier. The communications circuit board includes Ethernet/IP and/or Modbus TCP protocols, and in alternate forms includes RS-232 and RS-485 with Modbus RTU protocol, DeviceNet, Profibus DP, CanOpen, and/or EtherCat.