Redundant Single-Channel I/O Modules for Continuous Process Control
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Solution Overview
Problem
Existing distributed modular I/O systems lack redundancy for single-channel I/O submodules, leading to interruptions in operation when a submodule fails, which is undesirable in applications requiring continuous process control.
Innovation Solution
The implementation of a distributed modular I/O system with first and second network switches and system modules that provide redundancy, allowing single-channel I/O submodules to operate in parallel and ensuring continuous operation even if one fails, by connecting to both network switches and backplane circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single-channel I/O submodules are configured in a distributed modular I/O system, then the system provides flexibility and configurability for different I/O operations, but the system lacks redundancy and experiences interruptions when a submodule fails
Solution Approach 1:
The I/O device is segmented into multiple independent single-channel I/O submodules, each capable of performing specific I/O operations. This segmentation allows for flexible configuration while enabling individual submodule replacement without affecting the entire system, thus resolving the contradiction between configurability and reliability.
Solution Approach 2:
The system pre-configures multiple single-channel I/O submodules with different I/O capabilities within the same I/O device. This preliminary arrangement ensures that when one submodule fails, another can immediately take over its function, providing redundancy and maintaining system reliability without interrupting operation.
2Reliability
If redundant I/O submodules are implemented to ensure continuous operation, then fault tolerance is improved, but device complexity increases
Solution Approach 1:
Multiple single-channel I/O submodules are merged into a single integrated I/O device with a common base and terminal block. This merging approach provides redundancy and fault tolerance while maintaining a compact, manageable structure that does not significantly increase device complexity. The submodules share common resources while providing independent functionality.
Solution Approach 2:
The I/O device is designed with universal compatibility, allowing different types of single-channel I/O submodules to be interconnected and function together. This multi-functionality enables the system to handle various I/O operations through a unified interface, reducing complexity while maintaining reliability through redundant configurations.
3Ease of operation
If multiple single-channel I/O submodules are connected in parallel with network switches, then seamless replacement is enabled, but the network infrastructure and backplane circuits become more complex
Solution Approach 1:
Network switches and backplane circuits serve as intermediaries that facilitate communication and power distribution among multiple single-channel I/O submodules. These intermediaries enable seamless replacement by automatically routing signals and power, abstracting the complexity from the user while providing ease of operation for submodule installation and removal.
Data Source
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AI summary
An input/output (I/O) device for a distributed modular I/O system includes a base adapted to be connected to an associated support structure. A terminal block is connected to the base and includes a plurality of wiring connections adapted to be connected to field wiring of an associated controlled system. The I/O device further includes first and second I/O modules each including a plurality of removable single-channel I/O submodules that are each releasably connected to the base and each configured for a select I/O operation for input and output of data relative to the associated controlled system. One or more pairs of the single-channel I/O submodules can be configured to be redundant within or between the first and second I/O modules. Each of the single-channel I/O submodules is operatively connected to wiring connections of the terminal block through the base. The I/O device further includes first and second network switches connected to the base. The first and second network switches are adapted to be respectively connected to first and second backplane circuits. The I/O device further includes first and second system modules connected to the base and each respectively connected to both of the first and second network switches. The first and second system modules are also each respectively operatively connected to all of the removable single-channel I/O submodules of both of the first and second I/O modules such that the first and second system modules control communication of I/O data between the first and second network switches and the single-channel I/O submodules.