Reconfigurable I/O Module ASIC Switch Block for PLC Systems
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Solution Overview
Problem
Current industrial control systems face challenges in efficiently managing a large number of input/output (I/O) functions due to the need for multiple customized connector cables and limited slots in PLC racks, which is costly and time-consuming, especially in large-scale systems, and existing solutions are not effective in noisy industrial environments.
Innovation Solution
An I/O module with an application-specific integrated circuit (ASIC) that uses a switch block to reroute signals across multiple connection paths, allowing a single or group of I/O pins to handle multiple functions, reducing the number of components required and integrating noise protection within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple customized connector cables are used to connect different machine interfaces to the same I/O module, then the system can support diverse I/O functions, but the system complexity and cost increase significantly
Solution Approach 1:
The patent implements a universal I/O module design where a single module can perform multiple I/O functions through reconfigurable connection paths. The switch block enables the same physical I/O module to be dynamically assigned to different machine interfaces and functions, eliminating the need for multiple specialized modules and customized cables for each function type.
Solution Approach 2:
The patent introduces dynamic reconfigurability through a switch block that can real-time reassign connection paths within the I/O module. This dynamic switching capability allows the system to adapt to different I/O configurations without physical reconfiguration or replacement of hardware components, reducing cable and connector complexity while maintaining versatility.
2Quantity of substance
If PLC racks are extended to accommodate more I/O modules for large-scale systems, then more I/O points can be controlled, but the system cost and installation time increase
Solution Approach 1:
The patent enables a single I/O module to replace multiple specialized modules by implementing multiple I/O functions within one reconfigurable module. This consolidation reduces the total number of modules required in the PLC rack, eliminating the need for rack extensions while supporting large numbers of I/O points through dynamic reassignment of connection paths.
Solution Approach 2:
The patent merges multiple I/O functions and machine interface connections into a single reconfigurable I/O module. By combining what would traditionally require separate dedicated modules into one unified reconfigurable unit, the system reduces the total module count and eliminates the need for additional rack slots or rack expansion.
3Object-affected harmful factors
If ad hoc approaches with additional noise suppression components are used, then noise protection can be provided, but the system cost increases and scalability is reduced
Solution Approach 1:
The patent extracts the noise suppression function from external separate components and integrates it directly into the I/O module's internal circuitry. This integration eliminates the need for additional external noise suppression components while providing effective noise protection for the I/O signals, reducing system complexity and improving scalability.
Data Source
AI summary
An input/output module for use in an industrial control system and connectable to a programmable logic controller (PLC), the input/output module having an interface configured for an electrical connection to the PLC, a plurality of pins configured for connection to one of a plurality of peripherals, an application specific integrated circuit (ASIC) disposed in the I/O module and electrically coupled to a system controller, the ASIC having a plurality of connection paths, each path being configured for a function, and a switch block configured to reassign a signal from a first connection path of the plurality of connection paths to a second connection path of the plurality of connection paths.