Configurable Switch Emulator Module for Hazardous Environments
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Solution Overview
Problem
Control valve systems require a large inventory of different switches and sensors to accommodate various applications, leading to inefficiencies and increased costs due to the need for unique switches for each custom output type, especially in hazardous environments where standard switches may ignite flammable gases.
Innovation Solution
A target detection assembly with a detection member and an emulator module that can switch between different emulation circuits, allowing a single type of switch to emulate multiple output types, such as Namur N/O, Namur N/C, or SPDT switches, by reconfiguring the selection slots, thereby reducing the need for multiple switch types and enabling safe operation in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unique switches and sensors are selected for each application, then the output signal meets specific application requirements, but the inventory of switches becomes large and costs increase
Solution Approach 1:
The patent implements a universal switch assembly that can emulate multiple different switch types (NAMUR N/O, NAMUR N/C, SPDT, etc.) through a single device. The emulator module contains multiple emulation circuits that can be selectively activated based on the application requirements, allowing one switch to perform the functions of many different switch types without requiring separate inventory for each type.
Solution Approach 2:
The patent changes the output signal parameters (voltage levels, current levels, resistance values) through different emulation circuits within the same switch assembly. By adjusting which emulation circuit is active, the switch can output different signal types suitable for various applications, including hazardous environments, without physically changing the switch itself.
2Adaptability or versatility
If different switches are purchased for different output types, then the correct output signal is achieved, but the cost and complexity of installation increase
Solution Approach 1:
The switch assembly is designed as a universal platform that can provide multiple output types through selective emulation. The emulator module can be configured to emulate different switch types, and the indicator element shows which emulation mode is active, simplifying installation and configuration without requiring different physical switches for different applications.
Solution Approach 2:
The emulator module creates electrical copies or emulations of different switch output types within a single device. Instead of installing different physical switches, the system uses one switch that can copy the electrical characteristics and output signals of various switch types through its emulation circuits, reducing installation complexity.
3Ease of operation
If standard switches are used in hazardous environments, then installation is simple, but the switches may ignite flammable gases
Solution Approach 1:
The emulator module can change the output signal parameters to produce intrinsically safe voltage and current levels that are incapable of igniting flammable gases in hazardous environments. By selecting appropriate emulation circuits, the switch assembly provides output signals that meet safety requirements for hazardous areas while maintaining ease of installation similar to standard switches.
Data Source
AI summary
A target detection assembly includes a detection member adapted to generate a first input signal, and an emulator module is removably secured to the detection member. The emulator module includes an emulator housing assembly removably secured to the detection member and a selection portion is disposed on the emulator housing assembly. The selection portion is configured to be oriented in a first and second selection mode. In the first selection mode, a first emulation circuit disposed within the emulator housing assembly receives the first input signal, processes the first input signal, and outputs a first output signal that is different than the first input signal. In the second selection mode, a second emulation circuit disposed within the emulator housing assembly receives the first input signal, processes the first input signal, and outputs a second output signal that is different than the first input signal and the first output signal.