Removable Control Module for Industrial Device Programming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional industrial automation and control systems require expensive electrical isolation circuits to program high voltage devices, increasing overall costs due to the need for safe connection methods.
Innovation Solution
A control module with a removable attachment feature and a USB port for power and data communication, allowing decoupling from high voltage circuitry during programming to eliminate the need for isolation circuitry, enabling cost-effective programming without electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical isolation circuits are used to program high voltage industrial devices, then safety is improved, but device cost increases
Solution Approach 1:
The system is divided into two operational states: a first state where the control module is electrically coupled to the high voltage industrial device for normal operation, and a second state where the control module is decoupled from the high voltage device and coupled to a programming device for programming. This segmentation allows the system to achieve safety during programming by physically separating the programming circuitry from the high voltage circuitry, while eliminating the need for continuous electrical isolation circuits that would increase device cost.
Solution Approach 2:
The control module dynamically transitions between two coupling configurations: coupled to the high voltage industrial device during normal operation, and decoupled from the high voltage device but coupled to the programming device during programming operations. This dynamic reconfiguration enables the system to adapt its electrical connections based on operational mode, achieving safety during programming without requiring permanent isolation circuits.
2Ease of manufacture
If the control module is decoupled from high voltage circuitry during programming, then device cost is reduced by eliminating isolation circuitry, but programming capability is improved
Solution Approach 1:
The system separates the programming function from the high voltage control function by using distinct coupling configurations. During programming, the control module is decoupled from the high voltage device and coupled to the programming device, creating independent programming and operation pathways. This segmentation enables cost-effective programming by eliminating the need for expensive isolation circuits while maintaining full programming capability through the alternative coupling path.
Solution Approach 2:
The control module dynamically reconfigures its electrical connections based on operational mode: coupled to the high voltage device during normal operation, and decoupled to couple with the programming device during programming. This dynamic behavior enables the system to achieve both cost reduction (by eliminating continuous isolation requirements) and programming capability (by providing dedicated programming access).
Data Source
AI summary
A control module for an industrial device is provided. The control module includes a coupling feature configured to facilitate removable attachment of the control module with the industrial device and a communicative coupling feature configured to facilitate communication between the control module and the industrial device when coupled with a corresponding communicative coupling feature of the industrial device. The control module also includes a port configured to communicatively couple with a connector capable of supplying power and data communication, wherein the port is configured to receive power via the connector and exchange data with a computer via the connector.