Abstract:
An I/O circuit for use with an industrial controller provides an input circuit with low power dissipation through the use of a series connected substantially nonresistance impedance. An AC waveform input activates a light emitting diode (LED) bridge to provide an optical signal which illuminates a photosensitive solid-state switch thereby providing optical isolation between the industrial controller and the controlled process or machine. By using a series connected substantially nonresistance impedance, reduced current demand by the input circuit may be realized, which allows reduced power dissipation. As a result, the same circuit allows receiving input signals over a greater range, such as 120 volts AC and 240 volts AC, and allows significantly smaller components with closer spacing for a more compact design.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to I/O modules for industrial control systems and in particular to a low heat dissipation I/O module that may flexibly accommodate input AC waveforms over a range of AC voltages. 
     Industrial controllers are specialized computer systems used for the control of industrial processes or machinery, for example, in a factory environment. Industrial controllers differ from conventional computers in a number of ways. Physically, they are constructed to be substantially more robust against shock and damage and to better resist external contaminants and extreme environmental conditions. The processors and operating systems are optimized for real-time control and execute languages allowing ready customization of programs to comport with a variety of different controller applications. Typically, the controllers have a highly modular architecture that allows different numbers and types of input and output modules to be used to connect the controllers to the process or machinery to be controlled. This modularity is facilitated through the use of special “control networks” suitable for highly reliable and available real-time communication. Such control networks (for example, Ethernet IP) differ from standard communication networks (e.g. Ethernet) by guaranteeing maximum communication delays, for example, as obtained by pre-scheduling the bandwidth of the network, and/or providing redundant communication capabilities to high-availability. 
     As part of their enhanced modularity, industrial controllers may employ I/O modules dedicated to a particular type electrical signal and function, for example, detecting input AC or DC signals or controlling output AC or DC signals. Each of these I/O modules may have a connector system allowing them to be installed in different combinations in a housing or unit along with other selected I/O modules to match the demands of the particular application. Multiple units may be located at convenient control points near the controlled process or machine to communicate with a central industrial controller via a special control network such as Ethernet IP. Normally different I/O modules are required for receiving different AC and DC signals from the industrial processes or machinery, reflecting differences in the devices used. Different I/O modules may be used, for example, for receiving input signals operating around 120 volts AC as opposed to 240 volts AC. 
     The circuitry of the I/O module communicating with the industrial controller (controller-side) is also typically optically isolated from the circuitry communicating with the controlled process or machine (field-side) in order to prevent faults in the field-side from damaging the industrial control system or other I/O modules. For input circuits (such as AC input circuits) it can be necessary to receive the voltage signal from operation of the field-side circuitry to determine the frequency and/or amplitude of the signal from the controller-side. To prevent excess power from damaging the I/O module, a voltage dropping series resistor is often used converting the high voltage from the field-side into a lower voltage suitable for optical isolation to the controller-side. Such voltage dropping series resistors are often physically large to handle the necessary power dissipation and must be spaced apart to aid in dissipating the incident heat. 
     SUMMARY OF THE INVENTION 
     The present invention provides a series connected substantially nonresistance impedance for receiving the AC waveform and limiting the current of the AC waveform. By using a series connected substantially nonresistance impedance, current may be limited without the dissipation of heat energy. This is because the impedance of the substantially nonresistance impedance is comprised primarily of electrical reactance. Reactance may be characterized as the opposition of a circuit element to a change of electric current or voltage due to that element&#39;s electric or magnetic field. An electric field may resist the change of voltage on a circuit element while a magnetic field may resist the change of current. In contrast, a primarily electrical resistance may simply oppose the passage of electric current through the circuit element and dissipate heat energy. 
     It is thus a feature of at least one embodiment of the invention to provide reduced power dissipation, to receive input signals over a greater voltage range and/or achieve a more compact design. 
     The circuit also provides an optical isolator comprising a light emitting diode (LED) bridge coupled in series with the series connected substantially nonresistance impedance and operative to transmit light only when the magnitude of the voltage of the AC waveform is greater than a threshold, and having a photosensitive solid-state switch for receiving light from the LED bridge to provide an optically isolated signal. 
     It is thus a feature of at least one embodiment of the invention to provide an isolated monitoring of the input voltage 
     The LED bridge may comprise, for example, a first LED and a second LED wherein a cathode of the first LED is connected to an anode of the second LED and a cathode of the second LED is connected to an anode of the first LED. In this instance, the threshold may be a first predetermined threshold voltage for the first LED to conduct when the first LED is forward biased and a second predetermined voltage threshold for the second LED to conduct when the second LED is forward biased. 
     The photosensitive solid-state switch may comprise, for example, a photosensitive NPN transistor. The substantially non-resistance impedance may limit the current of the AC waveform through the LED to a predetermined operating current of the LED in a range of 120 volts AC to 240 volts AC. The series connected substantially nonresistance impedance may comprise an inductor, and may further comprise a capacitor in series with the inductor. The capacitor in series with the inductor may be for example a multi-layer ceramic capacitor. 
     The I/O module circuit may further include a microprocessor for receiving the optically isolated signal and determining the frequency and/or the amplitude of the optically isolated signal. It is thus a feature of at least one embodiment of the invention to determine frequency and/or amplitude from the signal. 
     The I/O module circuit may also include a terminal that is a screw type terminal. The I/O module circuit may also have a unit having multiple unit releasable electrical connectors, the unit supporting multiple I/O module circuits each having releasable electrical connectors connecting with the unit releasable electrical connectors, and wherein the unit includes elements for orienting and supporting the I/O module in the unit. 
     In another embodiment, the present invention provides an industrial control system comprising an industrial controller having at least one processor executing a stored program to receive input signals reflecting a state of a connected industrial process, a network providing a protocol ensuring a guaranteed maximum delay in a communication of data on the network system communicating with the industrial controller to communicate input signals therewith and an I/O module communicating with the network system to exchange the input signals therewith. The I/O module may further comprise a housing, a terminal supported by the housing for receipt of an AC waveform, and a circuit contained in the housing. The circuit provides a series connected substantially nonresistance impedance for receiving the AC waveform and limiting the current of the AC waveform. The circuit also provides an optical isolator comprising a light emitting diode (LED) bridge coupled in series with the series connected substantially nonresistance impedance and operative to transmit light only when the magnitude of the voltage of the AC waveform is greater than a threshold, and having a photosensitive solid-state switch for receiving light from the LED bridge to provide an optically isolated signal. 
     In yet another embodiment, the present invention provides a method of receiving an AC input signal in an I/O module in an industrial control system comprising receiving an AC waveform at a terminals of the I/O module connected in series with a substantially nonresistance impedance for limiting the current of the AC waveform and optically isolating the AC waveform using an optical isolator comprising a light emitting diode (LED) bridge coupled in series with the series connected substantially nonresistance impedance and operative to transmit light only when the magnitude of the voltage of the AC waveform is greater than a threshold, and having a photosensitive solid-state switch for receiving light from the LED bridge to provide an optically isolated signal. 
     These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a remote I/O unit of a type suitable for use with the present invention showing a housing having multiple I/O modules contained therein for communication with an industrial process via terminals and a remote industrial controller via a network cable; 
         FIG. 2  is a block diagram showing the I/O unit of  FIG. 1  in the context of the industrial control system incorporating multiple remote I/O units and an industrial controller; 
         FIG. 3  is a block diagram of the remote I/O unit showing connectors for attaching I/O modules installed in the I/O unit to a common bus communicating with the network cable and electrical power, and showing one I/O module providing an input circuit; 
         FIG. 4  is a detailed schematic of the input circuit of  FIG. 3  such as may receive an AC waveform from the input terminals to provide an isolated signal through an optical isolator; 
         FIG. 5  is aligned graphs showing the AC waveform and the switching of the LED bridge of the optical isolator for a short period of time; 
         FIG. 6  is a plot of the state of switching of the LED bridge of the optical isolator versus AC waveform voltage for the circuit of  FIG. 4 ; and 
         FIG. 7  is aligned graphs showing a change in the width of the pulse of  FIG. 6  with different amplitudes of AC waveforms allowing indirect amplitude monitoring. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIGS. 1 and 2 , an I/O block  10  may provide for a unit housing  12  having multiple openings  14  for orienting and supporting corresponding replaceable or permanently installed I/O modules  16 . The I/O modules  16  generally provide an electrical interface between an industrial controller  17  and an industrial process or machine  18 , the latter having actuators presenting loads  20  as powered by external field-side power sources  22  which may be AC sources (as shown) or DC sources as will be described. Each of the I/O modules  16  may have exposed screw terminals  24  for connecting circuitry of the I/O module  16  via electrical conductors  26  to the load  20  and field-side power source  22  of the industrial process or machine  18 . 
     The housing  12  of the I/O block  10  may be supported, for example, on a DIN rail  29  of a type known in the art or may provide for another mounting arrangement allowing it to be located close to the desired controlled loads  20 . The I/O block  10  may connect via a control network  28 , for example ControlNet or Ethernet IP, to industrial controller  17  for communication of control data between the I/O modules  16  of the I/O block  10  and the industrial controller  17 . 
     Generally, the industrial controller  17  will include at least one processor  30  executing a stored control program  32  contained in a communicating memory  34  to provide for communication with the control network  28  to exchange signals with the I/O block  10  for control of the industrial process or machine  18  according to a stored control program  32 . The stored control program  32  reads signals indicating the state of the industrial process or machine  18  (from sensors or the like) and writes outputs to the I/O block  10  to control the loads  20  according to those sensed inputs and the logic of the control program  32 . The industrial controller  17  may include a connection to a user interface terminal  35  (for example including a display, computer, keyboard, and mouse or the like) allowing programming and other control of the industrial controller  17  and providing for output of information to an operator. Industrial controllers  17  suitable for use with the present invention include, for example, programmable controllers commercially available from Rockwell Automation, Inc. 
     Generally, the I/O modules  16  of each I/O block  10  include an electrical isolation barrier  36  between the electrical power and circuitry of the industrial process or machine  18  and directly connected portions of the I/O module  16 , and the circuitry of the industrial control system including the industrial controller  17 , the network  28 , the I/O blocks  10  and remaining portions of the I/O modules  16 . Electrical isolation, as understood herein, refers to the portions of an electrical circuit and do not communicate by a DC electric path within the I/O block  10 . Circuitry on the side of the electrical isolation barrier  36  toward the industrial process or machine  18  will be termed “field-side” circuitry and circuitry on the side of the electrical isolation towards the industrial controller  17  will be termed “controller-side” circuitry. Electrical isolation, as is understood in the art, may be accomplished by an optical isolator or transformer that prevents DC conduction through the electrical isolation barrier  36  to prevent damage to the controller-side circuitry in the event of fault on the field-side circuitry. This isolation prevents simple sharing of electrical power between the circuits on the controller-side in the field-side by conductors spanning the isolation barrier  36 . 
     Referring now to  FIG. 3 , each I/O block  10  may provide a backplane  40  providing a set of electrically releasable or permanently connected electrical connectors  42  communicating with a backplane bus  44  providing parallel or serial digital communication and electrical power. Electrical power may be provided by a power supply  43 . The digital communication on the backplane bus  44  may be moderated by a unit controller  46  including network circuit  45  communicating with the industrial control network  28 . The unit controller  46  and network circuit  45  may be, for example, one or more electronic processors executing a stored program stored in memory or the like. 
     The electrical connectors  42  forming the backplane bus  44  may connect with corresponding electrical connectors  47  positioned at the rear of each I/O module  16  allowing electrical connection between controller-side circuitry of the I/O block  10  and the controller-side circuitry of the I/O module  16  for directly communicating data and power therebetween when an I/O module  16  is inserted into the I/O block  10 . Within each I/O module  16 , a module controller  48 , for example a microcontroller, may execute a stored program  50  to coordinate functions of the I/O module  16  by communicating with multiple input circuits  52 . Each of these input circuits  52  may provide internally for an electrical isolation barrier  36  between controller-side and field-side circuitry as will be described. Each of these input circuits  52  also communicate with a set of terminals  24  (only two shown for clarity) that may, for example, be screw type terminals releasably receiving electrical conductors  26 . 
     Referring now to  FIG. 4 , the input circuit  52  may receive an AC waveform  60  across the terminals  24 , for example a ground reference  62  at one terminal  24 ′ and the AC waveform at terminal  24 . The AC waveform will, in one embodiment, be at approximately 60 Hz and have a voltage between 120 and 240 volts AC. 
     The terminal  24  receiving the AC waveform may connect to a substantially nonresistance impedance element  64  comprising a series connected inductor  66  and capacitor  68 . Impedance element  64  may be sized to provide the necessary voltage drop and to limit current flow. It will be understood that a primarily reactive impedance element  64  may block current flow without dissipating substantial energy in contrast to a blocking resistance so that substantially no heat is generated in this current limiting process. Impedance element  64  may also comprise a large resistance value resistor  78  in parallel with capacitor  68  for allowing discharge of capacitor  68 , for example, upon removal of the module. In an alternative embodiment, one or more portions of impedance element  64  may be connected to terminal  24 ′ instead or in addition to terminal  24 . 
     Impedance element  64  in turn connects to a light emitting diode (LED) bridge  70  being part of an optical isolator  83 . The LED bridge  70  may comprise a first LED  72  and a second LED  74  wherein the cathode of the first LED  72  connects to the anode of the second LED  74  and the cathode of the second LED  74  connects to the anode of the first LED  72 . The impedance element  64  connects to the LED bridge  70  where the cathode of the second LED  74  connects to the anode of the first LED  72 . The LED bridge  70  in turn connects to ground reference  62  where the cathode of the first LED  72  connects to the anode of the second LED  74 . 
     When the first LED  72  or the second LED  74  of LED bridge  70  is turned on, that LED is illuminated providing optical signal  84  to phototransistor  86  of the optical isolator  83  finding the isolation barrier  36 . The first LED  72  may turn on, for example, when the AC waveform exceeds a first predetermined voltage, which may be a threshold voltage of about 1 volt for forward biasing the first LED  72 . The second LED  74  may turn on, for example, when the AC waveform falls below a second predetermined voltage, which may be then a threshold voltage of about −1 volt for forward biasing the second LED  74 . As a result, the LED bridge  70  is operative to transmit light when the voltage of the AC waveform is greater than the first and second predetermined voltage thresholds or when the voltage of the AC waveform is less than the first and second predetermined voltage thresholds. In addition, the LED bridge  70  is operative to not transmit light when the voltage of the AC waveform is within the first and second predetermined voltage thresholds. The phototransistor  86  may then send the output signal  55 , as described above, leading to module controller  48  shown in  FIG. 3 , using controller-side power  96  and controller-side ground  98  references isolated from the field-side. 
     Impedance element  64  may also connect to discrete elements, for example, resistor  92  and capacitor  94 , each in turn connecting to ground reference  62 . These discrete elements may provide additional filtering for the AC waveform and/or electrostatic discharge protection. 
     Referring now also to  FIGS. 5 and 6 , when the AC waveform  60  connected between terminals  24  and  24 ′ is at a voltage that is above the first predetermined voltage threshold of about 1 volt, and thus above the second predetermined voltage threshold of about −1 volt, LED bridge  70  is turned on providing optical signal  84  to phototransistor  86 . As a result, phototransistor  86  conducts to output signal  55 . 
     When the AC waveform  60  is between approximately the first predetermined voltage threshold of about 1 volt and the second predetermined voltage threshold of about −1 volt, LED bridge  70  is turned off and no optical signal  84  is provided to phototransistor  86 . As a result, phototransistor  86  stops conduction to output signal  55 . 
     When the AC waveform  60  falls below the second predetermined voltage threshold of about −1 volt, and thus below the first predetermined voltage threshold of about 1 volt, LED bridge  70  is turned on providing optical signal  84  to phototransistor  86 . As a result, phototransistor  86  conducts to the output signal  55 . 
     Referring now to  FIG. 7 , it will be understood that the width of the pulse of output signal  55  can be used to determine a coarse voltage level of the AC waveform  60  within AC waveform. For example, when the AC waveform  60  is 240 volts, the voltage swing will be steeper resulting in a relatively narrow pulse  90  measured in absolute time. Conversely, when the AC waveform  60 ′ is a relatively lower voltage, for example 120 volts, the voltage swing will be slower extending the pulse of base voltage  90 ′. In this way, operation of the I/O module at 120 or 240 volts may be determined and other simple voltage measurements may be made. 
     Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper,” “lower,” “above,” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “rear,” “bottom” and “side” describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first,” “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context. 
     When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     References to “a microprocessor” and “a processor” or “the microprocessor” and “the processor” can be understood to include one or more microprocessors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices. Furthermore, references to memory, unless otherwise specified, can include one or more processor-readable and accessible memory elements and/or components that can be internal to the processor-controlled device, external to the processor-controlled device, and can be accessed via a wired or wireless network. Co-pending patent applications entitled Output Module For Industrial Control With Sink And Source Capability And Low Heat Dissipation, Ser. No. 13/473,711, and Zero-Crossing Detector For Industrial Control With Low Heat Dissipation, Ser. No. 13/474,348, now U.S. Pat. No. 8,669,787, filed on even date herewith and assigned to the same assignee as the present invention are hereby incorporated by reference in their entirety. 
     It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as coming within the scope of the following claims. All of the publications described herein including patents and non-patent publications are hereby incorporated herein by reference in their entireties.