PLC Module Vertical Stacking via Spring-Loaded Pin Connectors
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Solution Overview
Problem
Industrial control systems, specifically programmable logic controllers (PLCs), face challenges in reducing size without compromising functionality due to the horizontal placement of modules and the use of cables and connectors for interconnections.
Innovation Solution
The implementation of a spring-loaded pin connector and corresponding receptacle system allows for vertical placement of printed circuit boards (PCBs) within PLC modules, enabling efficient space utilization and reducing the overall size of the PLC while maintaining full hardware functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cables and corresponding connectors are used for connecting I/O modules, then electrical connection between modules is achieved, but the PLC size increases and modules must be disposed horizontally
Solution Approach 1:
The patent transitions from horizontal module placement to vertical placement by changing the spatial dimension of module arrangement. Modules are stacked vertically with PCBs oriented perpendicular to each other, eliminating the need for horizontal cable routing and reducing overall PLC volume.
Solution Approach 2:
The patent extracts and eliminates the cable and connector components from the system by implementing direct PCB-to-PCB electrical connections through vertically stacked modules. This removes the intermediate connection elements that previously increased system volume.
2Volume of moving object
If modules are placed horizontally with cables for interconnection, then electrical communication between modules is established, but space utilization is inefficient
Solution Approach 1:
The patent merges the electrical connection function directly into the PCB structure through vertical stacking, eliminating separate cable and connector components. The PCB edges directly contact each other to establish electrical communication, simplifying the overall device structure.
Solution Approach 2:
The patent changes the spatial arrangement from horizontal to vertical stacking, allowing modules to be compactly arranged in the vertical dimension. This maximizes space utilization within the PLC housing while reducing the horizontal footprint.
3Volume of moving object
If vertical placement of modules is implemented, then PLC size is reduced, but connector design becomes more complex
Solution Approach 1:
The patent extracts the traditional cable and connector assembly from the system by implementing direct PCB-to-PCB contact through vertical stacking. This eliminates complex connector designs while achieving compact PLC dimensions.
Solution Approach 2:
The patent merges the electrical connection function directly into the PCB structure, where PCB edges make direct contact when modules are vertically stacked. This integration eliminates the need for separate connector components and simplifies the overall design.
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 allows for the vertical placement of PCBs, efficiently utilizing space within the PLC, thereby reducing its overall size without compromising the hardware's functionality or capabilities.
Implementation Method 1
The spring loaded pin connector includes a spring and a pin. The pin abuts an end of the spring. The spring is operable to move the pin relative to the housing of the male connector.
Implementation Method 2
The spring is operable to move the pin relative to the housing of the male connector
Data Source
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AI summary
In order to facilitate the vertical placement of modules (104, 106) within a PLC (100) and thus decrease the size of the PLC (100) without reducing the capability of the PLC (100), modules (104, 106) of the PLC (100) each includes a printed circuit board (PCB) (200, 202, 204), a spring loaded pin connector (214) supported by and in electrical communication with a first surface (206, 208) of the PCB (200, 202, 204), and a receptacle (216) supported by and in electrical communication with a second surface (206, 208) of the PCB (200, 202, 204). The spring loaded pin connector (214) and the receptacle (216) are in electrical communication with each other via the PCB (200, 202, 204).