Universal I/O Interposer System Modular Signal Conditioning
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Solution Overview
Problem
Current I/O signal conditioning systems in industrial control systems require substantial engineering effort for power management and diagnostics, especially during initial commissioning and when field devices are updated, and they lack flexibility in adapting to changing signal conditioning needs without disrupting the existing wiring.
Innovation Solution
A universal I/O interposer system that includes a base connected between field devices and controllers, with an interposer circuit carrier that can process I/O signals and provide power, allowing for easy replacement and configuration without disconnecting the base, and featuring access ports for diagnostics and various signal processing circuits such as pass-through, conditioning, and relay circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional signal conditioners are used in I/O systems, then signal conditioning functions are provided, but substantial engineering effort is required for power management and diagnostics during installation and updates
Solution Approach 1:
The system divides the signal conditioning functionality into separate, modular circuit carrier units that can be independently selected and installed in slots within the I/O system. Each circuit carrier provides specific signal conditioning functions (analog, digital, relay, etc.), allowing the system to be configured by assembling appropriate modules rather than requiring complex custom wiring and power management for each field device connection.
Solution Approach 2:
The I/O system provides a universal interface that can accommodate multiple types of circuit carriers (analog input, digital input, relay output, etc.) through standardized slots and connectors. This universal design allows the same physical infrastructure to support diverse signal conditioning needs without requiring separate engineering efforts for each device type, reducing overall system complexity while maintaining reliability.
2Adaptability or versatility
If field devices are updated or replaced in traditional I/O systems, then system improvements are achieved, but additional engineering effort is required to respond to changing power and power distribution requirements
Solution Approach 1:
The system allows dynamic reconfiguration of signal conditioning capabilities by simply swapping circuit carrier modules in standardized slots. When field devices are updated or replaced, the corresponding circuit carrier can be changed to match new power and signal requirements without affecting the overall system architecture or requiring re-engineering of power distribution pathways. This modular approach makes the system adaptable to changing requirements while maintaining consistent, simplified power management at the system level.
3Adaptability or versatility
If modular signal conditioners are used that require disconnecting I/O wiring for changes, then signal conditioning can be changed, but I/O wiring must be disconnected and reconnected
Solution Approach 1:
The system segments the signal conditioning function into removable circuit carrier modules that interface with fixed I/O wiring through standardized connectors. The circuit carriers are designed to be inserted or removed from slots without disturbing the main I/O wiring harness, which remains permanently connected to the system backbone. This allows signal conditioning capabilities to be changed by simply swapping modules rather than disconnecting and reconnecting field wiring.
Solution Approach 2:
The circuit carrier modules act as intermediary components between the fixed I/O wiring infrastructure and the variable signal conditioning requirements. These intermediaries absorb the complexity of different signal types and conditioning needs, allowing the permanent I/O wiring to remain unchanged while the modular carriers are swapped to adapt to different field devices. This mediator approach eliminates the need to disconnect wiring when changing signal conditioning functionality.
4Reliability
If extensive testing of I/O signal quality is performed during commissioning, then proper installation and operation are assured, but commissioning time and complexity increase
Solution Approach 1:
The circuit carrier modules are pre-configured and pre-tested at the factory to ensure proper signal conditioning functionality before being installed in the field. Each module comes with predetermined wiring configurations and signal parameters already optimized for its specific function. This preliminary preparation eliminates the need for extensive on-site testing and adjustment during commissioning, as the modules are designed to work correctly upon installation, thereby reducing commissioning time while maintaining installation correctness.
Data Source
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AI summary
A universal I/O interposer system for processing an I/O signal transmitted between an I/O field device and a controller, the system includes a base connected between the field device and the controller and a number of connector halves attached to the base. An interposer circuit carrier includes a corresponding connector half and includes a signal processing circuit for processing an I/O signal being transmitted between an I/O field device and a controller. An interposer circuit carrier can be changed without disconnecting the base from the field device or controller.