Smart Terminal Block Integration for Modular I/O Power Isolation
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Solution Overview
Problem
Existing modular I/O systems face inefficiencies due to the need for separate auxiliary wiring connectors, which complicate wiring, reduce power availability, and increase maintenance complexity, especially when additional power and circuit breaking capabilities are required.
Innovation Solution
The integration of a modular I/O system with a terminal block and auxiliary wiring device that includes power converters, fuses, and knife disconnects, allowing for direct connection and disconnection of field devices without separate wiring, and enabling higher power supply and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate auxiliary wiring connectors are used to provide additional wiring connections, then the required number and type of wiring connectors can be achieved, but the wiring system becomes more complicated and less efficient
Solution Approach 1:
The patent combines the terminal block and auxiliary wiring connector into a single integrated unit. The auxiliary wiring connector is positioned adjacent to the terminal block with electrical connections that combine signal and power pathways, eliminating the need for separate auxiliary wiring devices and reducing overall system complexity while maintaining wiring versatility.
2Adaptability or versatility
If separate auxiliary wiring connectors are used, then additional wiring connections are available, but maintenance and service becomes more difficult
Solution Approach 1:
By integrating the auxiliary wiring connector with the terminal block into a single replaceable unit, the patent simplifies maintenance operations. When failure occurs, the entire integrated assembly can be replaced as one module, and the unified structure makes it easier for maintenance personnel to understand the wiring pattern and duplicate connections.
3Adaptability or versatility
If power is supplied to auxiliary wiring device from I/O module, then auxiliary wiring is enabled, but power availability is limited due to heat dissipation requirements
Solution Approach 1:
The patent extracts the power supply function from the I/O module and provides it through separate power terminals on the integrated terminal block/auxiliary wiring connector assembly. This allows the I/O module to focus on signal processing while the terminal block receives power directly from external sources, thereby increasing overall power availability without being constrained by the I/O module's heat dissipation capabilities.
4Adaptability or versatility
If field wires are lengthened and routed to separate auxiliary wiring device, then connection is achieved, but wiring system becomes more complicated
Solution Approach 1:
The integrated design positions the auxiliary wiring connector adjacent to the terminal block with built-in electrical connections between them. This allows field wires to connect to either component without requiring lengthy extensions or complex routing, as the signal and power pathways are already unified within the single assembly, thereby improving wiring efficiency and ease of operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This integration simplifies installation, reduces wiring errors, enhances power capacity, and improves maintenance efficiency by providing integrated power conversion and circuit breaking within the terminal block, reducing thermal stress on I/O modules.
Implementation Method 1
a power converter for supplying a prescribed power signal to the field device
Data Source
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AI summary
A modular I/O device includes a terminal base with a terminal block that includes a plurality of wiring connectors. An auxiliary wiring device includes a plurality of auxiliary wiring connectors and is selectively physically connectable to the terminal base in an operative position and selectively physically removable from the terminal base. The terminal block and auxiliary wiring connector can be coupled to an I/O module. One or more of the I/O module terminal block and auxiliary wiring connector can include electrical or electronic components included converters, fuses, switches, etc.