Redundant Terminal Block Layout for Modular Process Control I/O
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Solution Overview
Problem
Existing process control systems lack a simple and safe method to provide redundant I/O channels, which is crucial for ensuring high availability in critical production environments.
Innovation Solution
A terminal block unit for modular process control systems that houses two redundant signal conditioning units in a pair of adjacent slot elements, providing a parallel connection to a field device without additional contact elements, allowing for flexible configuration of redundancy on a channel-by-channel basis and enabling late decision-making on redundancy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant signal conditioning units are provided for all I/O channels, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The terminal block unit is divided into two separate slot elements (first and second slot elements) that can independently receive signal conditioning units. This segmentation allows selective redundancy configuration where only critical channels receive redundant units, while non-critical channels use single units, thus improving reliability where needed without increasing overall system complexity.
Solution Approach 2:
The patent enables different redundancy configurations for different I/O channels based on their specific requirements. The terminal block unit can accommodate both redundant and non-redundant signal conditioning units within the same unit, allowing local optimization of reliability versus complexity for each channel based on its importance and operational requirements.
2Reliability
If redundant signal conditioning units are provided for all I/O channels, then system reliability is improved, but cost increases
Solution Approach 1:
By segmenting the terminal block unit into two distinct slot elements, the system allows selective placement of redundant signal conditioning units only in slots where high availability is required. This reduces the total quantity of redundant hardware needed compared to providing redundancy for all channels, thereby lowering cost while maintaining necessary reliability.
Solution Approach 2:
The patent enables differential redundancy configuration where each slot element can be independently configured based on the specific reliability requirements of the connected field device. This local quality approach ensures that redundant hardware is deployed only where necessary, optimizing the balance between reliability improvement and cost control.
3Reliability
If additional contact elements are used to connect terminal block unit to slot elements, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The terminal block unit merges the connection function into the housing structure itself. The housing is designed with integrated connection elements that directly engage with the slot elements, eliminating the need for separate additional contact elements. This merging approach maintains connection reliability while reducing overall device complexity.
Solution Approach 2:
The housing of the terminal block unit serves multiple functions: it provides mechanical support, structural protection, and direct electrical connection to the slot elements. This multi-functionality eliminates the need for dedicated separate contact elements, reducing complexity while maintaining reliable connections.
Data Source
AI summary
A terminal block unit for an input/output device of a modular process control system includes two slot elements configured to receive two redundant signal conditioning units. The terminal block unit is configured to be housed in a pair of two adjacent slot elements of a module termination unit of an input/output device. The terminal block unit provides a parallel connection of the redundant signal conditioning units to a field device.