Universal I/O Module With Dynamic Resistance Reconfiguration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial control systems face limitations in flexibility and resource management due to the need for multiple I/O modules to match varying I/O requirements, leading to complexity, additional costs, and inconvenience when process or machine configurations change.
Innovation Solution
A universal I/O module that dynamically adjusts resistance in channels using a processor or voltage divider to support multiple modes such as digital input/output, analog input/output, and HART communications, allowing for infinitely configurable channel resistances without physical resistors, thereby supporting various I/O types without hardware changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple dedicated I/O modules are used to match varying I/O requirements, then the system can properly support different I/O types (analog, digital, HART), but the device complexity and quantity of components increase
Solution Approach 1:
The patent implements a universal I/O module that can dynamically adapt to support multiple I/O types (analog input, analog output, digital input, digital output, HART communication) through a single device. The module uses a variable resistance device controlled by a microcomputer to reconfigure its electrical characteristics based on the required I/O type, eliminating the need for multiple dedicated modules and reducing system complexity while maintaining full adaptability
Solution Approach 2:
The patent employs a variable resistance device (such as a digitally controlled potentiometer or electronic rheostat) that can dynamically adjust its resistance value under microcomputer control to match the requirements of different I/O types. This dynamic reconfiguration allows the same physical channel to adapt its electrical characteristics in real-time, enabling a single module to replace multiple static modules
2Adaptability or versatility
If multiple dedicated I/O modules are maintained for different I/O types, then proper I/O matching is achieved, but the manufacturing cost and resource requirements increase
Solution Approach 1:
By designing a single universal I/O module that can be reconfigured for different I/O types through software control and variable resistance adjustment, the patent eliminates the need for users to purchase, maintain, and store multiple different module types. This reduces manufacturing costs, inventory requirements, and resource consumption while maintaining the ability to support all required I/O configurations
Solution Approach 2:
The patent changes the electrical parameters (particularly resistance) of the I/O channel dynamically based on the required I/O type. By controlling the variable resistance device through digital signals from a microcomputer, the module can adjust its electrical characteristics to match different I/O requirements without physical hardware changes, reducing manufacturing complexity and cost
3Adaptability or versatility
If I/O modules are replaced when function changes are needed, then the system adapts to new requirements, but implementation time and operational inconvenience increase
Solution Approach 1:
The patent enables dynamic reconfiguration of I/O channel functions through software control of the variable resistance device and channel configuration registers. When a function change is needed, the microcomputer simply updates the control parameters electronically, allowing instantaneous or near-instantaneous reconfiguration without physical module replacement, thereby eliminating implementation delays and operational inconvenience
Solution Approach 2:
The patent replaces the mechanical/physical process of module replacement with an electronic/software-based reconfiguration process. Instead of physically removing and installing different I/O modules, the system uses digital control signals to reprogram the universal module's behavior, substituting a fast electronic operation for a slow mechanical process
4Device complexity
If fixed resistance channels are used in I/O modules, then the circuit design is simplified, but the adaptability to different I/O types is reduced
Solution Approach 1:
The patent introduces a variable resistance device that can be controlled by a microcomputer to change the resistance value in the I/O channel based on the required I/O mode. This allows the same physical channel to present different electrical characteristics (e.g., different source impedances for analog inputs, different pull-up resistances for digital inputs) as needed, maintaining circuit design simplicity while achieving full adaptability to different I/O types
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
The solution provides a flexible and adaptable I/O channel that can support multiple I/O types, reducing the need for multiple modules, minimizing PCB space, and allowing for active power dissipation control, thus enhancing system flexibility and reducing implementation time and costs.
Implementation Method 1
A variable resistance device in a channel interfacing with industrial control equipment provides a resistance in the channel. A control circuit controls the variable resistance device to adjust the resistance in the channel for a given mode selected from multiple modes.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An industrial control I/O module for interfacing with industrial control equipment, such as sensors and actuators, can be configured to dynamically provide differing resistances in each channel as may be required for reliably achieving particular modes of operation in the channel. Providing differing resistances in such channels flexibly allows different modes in the channel to provide universal I/O capability. Modes of operation could include, for example, digital output, digital input, analog output, analog input and the like, in the same channel, but at different times. In one aspect, a processor or voltage divider can be used to control an amplifier, with feedback, driving a transistor in a channel to dynamically adjust resistance in the channel by selectively biasing the transistor to achieve a resistance in the channel suitable for the selected mode.