Quick-connector conversion system for safety controller
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Solution Overview
Problem
Existing safety controllers face complexity in wiring and connectivity with safety devices, leading to potential miswiring and increased configuration difficulties, especially with configurable systems.
Innovation Solution
A quick-connector conversion system featuring a front cover with apertures for pluggable connector ports that align with a rear module's I/O terminals, simplifying connections by converting screw-type terminals to pluggable connectors, and using color-coded ports and indicator lights to ensure proper connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw-type terminals are used for connecting safety devices to the safety controller, then reliable electrical connection is achieved, but wiring complexity and potential for miswiring increases
Solution Approach 1:
The patent replaces the mechanical screw-terminal connection system with a pluggable connector system. The pluggable connector allows for tool-free, simplified connection while maintaining reliable electrical contact through spring-loaded or snap-fit mechanisms that ensure consistent electrical connection without requiring threading or tightening operations.
Solution Approach 2:
The pluggable connector acts as an intermediary component between the safety device and the safety controller terminal. This intermediate element simplifies the connection interface while maintaining reliable electrical contact, serving as a mediator that bridges the gap between simple plugging action and reliable electrical connection.
2Adaptability or versatility
If multiple configurable options are provided in the safety controller, then user needs are better met, but configuration difficulty and potential for misconfiguration increases
Solution Approach 1:
The patent applies local quality by providing specific visual indicators (color-coding, LED lights) at each connector port to indicate its function and connection status. This localized information helps users quickly identify the correct port for their device without needing to understand the entire configuration system, thereby maintaining adaptability while improving ease of operation.
Solution Approach 2:
The patent uses color-coding of connector ports and corresponding visual indicators to provide intuitive information about port function and connection status. Different colors indicate different device types or connection states, allowing users to quickly configure the system without complex documentation, thus maintaining versatility while improving ease of operation.
3Ease of operation
If pluggable connectors are used instead of screw terminals, then connection simplicity is improved, but connection reliability may be compromised
Solution Approach 1:
The patent replaces the screw-terminal mechanical system with a pluggable connector system that uses spring-loaded contacts or snap-fit mechanisms. These mechanisms provide reliable electrical connection through elastic deformation and continuous contact pressure, achieving both simplicity of connection and reliability of electrical contact.
Solution Approach 2:
The patent employs contact designs with curved or rounded contact surfaces that distribute mechanical stress and ensure consistent electrical contact. The curved contact surfaces allow for self-alignment and maintain reliable connection even with minor variations in insertion precision, thereby achieving both simplicity and reliability.
4Reliability
If visual indicators are added to indicate proper connectivity, then miswiring risks are reduced, but device complexity increases
Solution Approach 1:
The patent uses color-coded connector ports and LED visual indicators to provide immediate feedback on connection status. The LEDs change color or illuminate to indicate proper connection, thereby reducing miswiring risks. This approach adds minimal complexity while significantly improving connection accuracy through intuitive visual feedback.
Solution Approach 2:
The patent incorporates visual feedback mechanisms (LED indicators) that immediately inform users whether a connection is proper or improper. This real-time feedback allows users to correct miswiring immediately, reducing the risk of operational errors. The feedback system adds minimal complexity while dramatically improving connection accuracy.
Data Source
AI summary
Apparatus and associated methods relate to a quick-connector conversion system having a front cover and a rear module. In an illustrative example, the front cover includes apertures from which a plurality of connector ports extend through. Each connector port of the plurality of connector ports is in electrical communication with a first communication module. A rear module includes a second communication module electrically connected to a plurality of input/output (I/O) terminals such that when the front cover aligns with the rear module, the first communication module pluggably connects to the second communication module. When the first communication module and the second communication module are pluggably connected, the plurality of connector ports electrically connects to the plurality of the I/O terminals.