Programmable I/O Module Reduces Custom Cable Complexity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing industrial control systems require custom cable configurations and extensive hand-wiring due to non-standard connectors and power supply issues, leading to increased complexity, cost, and time in system design and maintenance.
Innovation Solution
A programmable input/output module with a microprocessor and application-specific integrated circuits (ASICs) that uses standard cables to direct signals between devices, eliminating the need for custom cable harnesses and reducing hand-wired connections by enabling flexible signal routing and power supply management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom cable configurations and hand-wiring are used to connect sensors and actuators to control systems, then specific wire interconnections can be achieved, but system complexity and design time increase significantly
Solution Approach 1:
The patent implements a universal connector system where a single connector design can accommodate multiple signal types and configurations. The connector includes multiple contacts that can be programmed to different functions, allowing one connector type to replace multiple custom cable designs. This enables the same physical connector to serve various purposes through software configuration rather than requiring different custom cables for each application.
Solution Approach 2:
The patent employs programmable I/O modules that can dynamically reconfigure signal routing and connector functions without physical rewiring. The system allows changes in connection configurations through software programming, enabling the same hardware to adapt to different wiring requirements. This dynamic reconfiguration capability eliminates the need for static custom cable designs and reduces system complexity.
2Reliability
If individual wire connections via terminal blocks are used, then electrical connections can be made, but the arrangement is not convenient for facilitating easy connection of loads
Solution Approach 1:
The patent combines multiple functions into a single integrated connector assembly. Instead of separate terminal blocks for different signal types, the universal connector integrates power, ground, and multiple signal contacts in one unit. This merging of functions into a single connectable component significantly improves ease of operation while maintaining reliable electrical connections through standardized contact designs.
3Ease of manufacture
If connectorized wire harnesses are used, then connections can be made, but the connectors are rarely configured to accept sensor signals or provide actuator power directly
Solution Approach 1:
The patent designs universal connectors with multiple contacts that can be programmed to accept various sensor signals and provide different actuator powers. The same physical connector can be configured through software to work with different device types, eliminating the need for specialized connectors for each application. This universality maintains ease of manufacture with standardized components while achieving broad adaptability.
Solution Approach 2:
The patent utilizes programmable parameters within the I/O modules to change the electrical characteristics and signal configurations of the connectors. By modifying software parameters, the same connector can be adapted to different voltage levels, signal types, and communication protocols, achieving versatile compatibility without requiring different physical connector designs.
4Adaptability or versatility
If extensive hand-wiring is performed to effect interconnections, then specific device connections can be achieved, but cost and implementation time significantly increase
Solution Approach 1:
The patent incorporates pre-configured universal connectors with standardized contact arrangements that are designed in advance to accommodate multiple signal types. The I/O modules come with pre-programmed configurations that can be quickly adapted to different applications without requiring extensive on-site wiring work. This preliminary preparation of connector designs and configurations significantly reduces implementation time while maintaining the ability to achieve specific device interconnections.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An input/output module for implementing directions from a controller for sending and receiving signals to and from devices. The input/output module includes a microprocessor for communication with, and receiving programming from the controller. The input/output module further includes device communication connectors, each having number of pins, each pin for interconnection with a cable conductor to a device. The input/output module has an ASIC for each of the pins, providing a controlled interface with the corresponding pin. Each ASIC has interconnection apparatus, selectable by the microprocessor for providing a particular interface with the pin served by the ASIC.