Terminal Base Adapter for Fast Plant IO Module Renewal
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Solution Overview
Problem
Conventional control IO module renewal processes are time-consuming and prone to incorrect connections due to the need to disconnect and reconnect field wiring cables, and existing solutions like Patent Document 1 face stability issues with external line connectors and require structural changes.
Innovation Solution
A plant control device with a terminal base adapter that converts IO signals and supports the new control IO module without disconnecting existing wiring, allowing for stable operation and minimizing structural changes during renewal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the field wiring cable is disconnected from the existing control terminal base and reconnected to a new control terminal base, then the control IO module can be renewed, but the renewal process takes a lot of time and is prone to incorrect connections
Solution Approach 1:
An adapter is introduced as an intermediary component between the existing control terminal base and the new control IO module. The adapter maintains the field wiring cable connections at the existing base while providing connection points for the new IO module, eliminating the need to disconnect and reconnect cables during renewal.
Solution Approach 2:
The system is segmented into three independent components: the existing control terminal base, the adapter, and the new control IO module. This segmentation allows each component to be handled independently, with the adapter serving as a bridge that connects the old base to the new module without requiring cable disconnection.
2Reliability
If the existing external line connector supports the weight of the external line cable, then the connector may come off from the relay unit, but installing support structures requires structural changes to the control panel
Solution Approach 1:
The support function is segmented from the existing control terminal base and embodied in the separate adapter component. The adapter includes dedicated support structures that bear the cable weight independently, preventing the connector from coming off while avoiding structural changes to the main control panel.
Solution Approach 2:
The adapter acts as an intermediary that introduces new support structures between the existing base and the new IO module. These support structures handle the cable weight without requiring modifications to the original control panel structure.
3Ease of manufacture
If the relay unit and new IO unit are electrically connected by in-panel IO cable, then connection can be established, but wire connection requires careful work in consideration of pin assignment differences
Solution Approach 1:
The adapter serves as an electrical intermediary that includes connection terminals for both the existing control terminal base and the new control IO module. It handles the pin assignment differences internally, allowing straightforward connection without requiring careful wire matching or consideration of pin configurations.
Solution Approach 2:
The adapter reproduces or copies the electrical connection interface in a standardized manner, providing uniform connection points that abstract away the underlying pin assignment differences between the old base and new module.
Data Source
AI summary
A plant control device includes: a terminal base where a wiring is connected which is connected to each of multiple devices installed in a plant; a control IO module where an IO signal is input or the IO signal is output; and a terminal base adapter disposed between the control IO module and the terminal base, the terminal base adapter being configured to convert, by a predetermined logic, an IO signal input from at least one of the multiple devices or the IO signal input from the control IO module. The terminal base adapter is mountable on the terminal base and includes a second electrical connector which is mounted with a first electrical connector disposed on the control IO module.