Patent Publication Number: US-2023145122-A1

Title: Profile cable switching

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the filing benefits of U.S. provisional application, Ser. No. 63/277,218, filed Nov. 9, 2021, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention is directed to network systems, and in particular to ASi-type cables and inter-connected modules, e.g., controllers, input devices, and output devices. 
     BACKGROUND OF THE INVENTION 
     Industrial systems, with sensors, actuators and other output devices, and controllers are commonly interconnected via communication networks. One such example networking system is the actuator sensor interface (ASi) used in various automation systems. The ASi networking system is designed to interconnect input devices (e.g., ON/OFF switches and sensors), output devices (e.g., actuators), and logic/controller modules in manufacturing and process applications. ASi compliant systems can interconnect the devices using just two-conductor wire cables. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide systems and methods for power switching (e.g., emergency stop switching) without the use of costly and time-consuming cable terminations at multiple devices. The network module of the present invention is configured to provide switched auxiliary (AUX) power for emergency stop (“E-stop”) system functionality in a network system. The network module comprises a controller module and a switching module. The controller module is configured to control the switching actions of the switching module. The switching module is configured to control the passage of power through a switched AUX cable. The switching module is configured to receive an unswitched AUX cable and a switched AUX cable. The switching module is further configured to control the passage of power from the unswitched AUX cable to the switched AUX cable. 
     In a network module of the present invention, the network module is configured to provide switched auxiliary (AUX) power for E-stop system functionality in a network system. The network module includes a switching module and a controller module. The switching module is configured to control the passage of power through a switched AUX cable for E-stop functionality. The switching module is configured to receive an unswitched AUX cable and the switched AUX cable. The controller module is communicatively coupled to a communications cable. The controller module is configured to control the switching actions of the switching module as defined by switching instructions received via the communications cable. 
     In an aspect of the present invention, the controller module is configured to receive switching instructions for controlling the switching module via a communications cable that passes through the network module. 
     In another aspect of the present invention, the unswitched AUX cable and the switched AUX cable are both coupled to the switching module via respective connection modules. One or more of the connection modules coupling the unswitched AUX cable and the switched AUX cable to the switching module may be part of the switching module or physically separated from the switching module. The communications cable is coupled to the controller module via another connection module. In a further aspect, the connection modules are configured to couple cables to the respective modules via insulation displacement connections. 
     In a further aspect of the present invention, a method for providing switched auxiliary (AUX) power for E-stop system functionality in a network system includes providing a switching module. Switching actions of the switching module are controlled via signals received from a communications cable. The switching module receives an unswitched AUX cable and a switched AUX cable. The method also includes controlling the passage of power from the unswitched AUX cable to the switched AUX cable. 
     The unswitched AUX cable is configured to pass through the network module. The switched AUX cable originates in the switching module and extends outward from the network module. 
     At least one of the unswitched AUX cable, the switched AUX cable, and the communications cable are actuator sensor interface (ASi) cables. 
     In a further aspect of the present invention, the switching module comprises one or more relays, each relay configured to control the passage of power through the switched AUX cable. 
     Thus, a switching module of a network system of the present invention is configured to provide switched auxiliary (AUX) power for E-stop system functionality in the network system. An exemplary network module is configured to receive network cables (e.g., ASi profile network cables) and to couple to them using insulation displacement connections. The exemplary network module receives a communications cable and an unswitched AUX cable, as well as originating a switched AUX cable. The exemplary network module includes a controller module and a switching module. The controller module is configured to control the passage of power through the switched AUX cable by controlling the passage of power from the unswitched AUX cable to the switched AUX cable. The switching module is configured to control the passage of power through the switched AUX cable via control signals received from the controller module. The exemplary insulation displacement connectors allow for an efficient coupling of signals/power to internal components without requiring the additional hardware and wiring needed to physically land the network cables in the network module. 
     These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a block diagram illustrating the interconnection of components via a network system in accordance with the present invention; 
         FIG.  2    is a block diagram illustrating an exemplary switching module for a network module of a network system in accordance with the present invention; 
         FIG.  3 A  is a block diagram of another exemplary switching module for a network system in accordance with the present invention; 
         FIG.  3 B  is a block diagram of a conventional switching module for a network system; and 
         FIG.  4    is a block diagram illustrating an exemplary connection module coupling to a profile (flat) cable in accordance with the present invention; 
         FIG.  5    is a block diagram of an exemplary cable terminal for mechanically landing profile cables and other interconnecting cables; 
         FIG.  6    is a block diagram of an exemplary ASi network module with a switching module for a network system in accordance with the present invention; 
         FIG.  7    is a side view of the ASi network module of  FIG.  6    illustrating the coupling of a facing portion to a back plate of the ASi network module; 
         FIG.  8    is an interior view of the back plate of the ASi network module of  FIG.  7    illustrating the placement of exemplary ASi network cables in accordance with the present invention; 
         FIG.  9    is a perspective view of an exemplary ASi network module with a switching module for a network system in accordance with the present invention; and 
         FIG.  10    is an interior view of a back plate of the ASi network module of  FIG.  9   . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention will now be described with reference to the accompanying figures, wherein numbered elements in the following written description correspond to like-numbered elements in the figures. 
     Methods and systems of the present invention provide switched auxiliary (AUX) power for a safety-rated output bus (E-stop functionality) through the uses of network-based safety functionality (via a safety controller), and the use of a generic power bus, without the use of costly mechanical wire terminations and wire pulls. Thus, such an exemplary system may provide for E-stop signal switching onto a switched bus system without the use of costly and time-consuming wire terminations at multiple devices (and associated locations). Safety systems require some combination of input devices (E-stop pull cords, light curtains, etc.) to be connected to a logic unit (e.g., controller, such as a processor or micro-processor) through either E-stop wiring or redundant safety rated protocols. This logic unit evaluates the E-stop input devices to determine when it is safe to turn on the corresponding output devices (via a switched power bus). 
       FIG.  1    illustrates an exemplary network  100  for monitoring interconnected input/output devices and for detecting faults. A pair of logic units  102   a,    102   b  are interconnected with input devices  104   a,    104   b  and output devices  106   a,    106   b,  respectively. As described herein, such logic units  102 ,  102   b  may comprise a processor or micro-controller, a memory, input/output devices, required circuitry, and software. Such input devices can include, for example, input switches, sensors, and other similar devices configured to input control signals, monitor control or sensor signal outputs, and/or measure signal levels (e.g., sensor outputs). The output devices can include, for example, actuators, motors, and other similar devices configured to perform an instructed motion or action. The input devices  104   a,    104   b  and the output devices  106   a,    106   b  are interconnected with the logic units  102   a,    102   b,  respectively, via interconnecting means  101 . In one exemplary embodiment, the interconnecting means  101  includes an ASi network or a similar network system. In another embodiment, the interconnecting means is a network system that includes wiring configured to carry data and control signals between modules (e.g., input/output devices, logic devices or controllers, distribution modules or relays, E-Stop modules with switched auxiliary power, and control modules). As illustrated in  FIG.  1   , the logic devices  102   a,    102   b  are also configured to provide fault detection  103  of the output devices  106   a,    106   b.  The logic devices  102   a,    102   b  are also configured to perform cross monitoring  105  of each other. The wiring/cabling (i.e., the interconnecting means  101 ) necessary for interconnecting the components of the network  100  (and performing the desired monitoring and fault detection) requires some combination(s) of series and parallel wiring/cabling. For example, in one embodiment, an exemplary ASi network cable is configured as a flat, asymmetric two-wire flat cable, where the wiring is stripped and landed inside the several modules (e.g., input/output devices, logic devices, distribution modules, E-Stop modules with switched auxiliary power, and control modules) of the system. 
       FIG.  2    illustrates an exemplary network module  200  configured to provide a safety-rated output bus (e.g., an ASi network switching module or other similar network interconnect providing a switched power output) through the use of a networked safety controller  202  that provides the desired network-based safety functionality, and also allows the use of a generic power bus (e.g., an unswitched power bus). As illustrated in  FIG.  2   , the networked safety controller  202  (comprising a processor or micro-controller, memory input/output devices, required circuitry, and software), communicatively coupled to a communications cable  204 , is configured to control the passage of power from an unswitched AUX cable  206  (an unswitched power bus) to a switched AUX cable  208  (a switched power bus). The switched AUX cable  208  may be configured as a switched E-Stop power bus (i.e., a switched AUX cable coupled to a fail-safe control switch that when actuated causes the operation of an associated process or equipment to be shut down or stopped via the switched power bus). 
     The networked safety controller  202  is configured to control the passage of power from the unswitched AUX cable  206  to the switched AUX cable  208  via internal safety relays  210 . The network module  200  is configured to couple to the communications cable  204 , the unswitched AUX cable  206 , and the switched AUX cable  208  via, for example, insulation displacement connections. The exemplary network module  200  uses a generic power bus (the unswitched AUX cable  206 ) which passes through the network module  200  to originate the switched AUX cable  208  without any end terminations or complex wiring. The networked safety controller  202  controls the internal safety relays  210  (of the networked safety controller  200 ), via control signals, in response to signals (e.g., E-stop control signals) received via the communications cable  204 . 
     As illustrated in  FIG.  3 A , an exemplary network module  300  is configured to use a generic, unswitched AUX cable  306  (such as the unswitched AUX cable  206 ), which passes through the network module  300  via insulation displacement connection means (e.g., connection module  303 ). That is, each connection module  303   a,    303   b,    303   c  comprises at least one insulation displacement connection means for connecting or coupling to a corresponding cable  304 ,  306 , or  308 , respectively. The network module  300  includes a safety relay module  310  with a plurality of relays that act upon the unswitched AUX cable  306  to originate a switched AUX cable  308  that receives its power from the unswitched AUX cable  306 . As illustrated in  FIG.  3 A , the safety relay module  310 , via its relays, controls the passage of power from the unswitched AUX cable  306  to the switched AUX cable  308 . Such switching may also include E-stop switching functionality. A network controller  302  controls the switching actions of the safety relay module  310  as defined by switching instructions received from a communications cable  304 . As discussed herein, the network controller  302  comprises a processor or micro-controller, memory, input/output devices, required circuitry, and software. As illustrated in  FIG.  3 A , the communications cable  304  is coupled to the network controller  302  via a connection module  303   a.    
     The unswitched AUX cable  306  and the switched AUX cable  308  are coupled to the safety relay module  310  via a pair of connection modules  303   b,    303   c.  As illustrated in  FIG.  4   , in one embodiment, the connection modules  303  are configured to provide insulation displacement connections to individual wires of the profile (flat) cables. As illustrated in  FIG.  3 A , the connection modules  303   b,    303   c  (for coupling the unswitched AUX cable  306  and the switched AUX cable  308 ) may be either implemented as part of the relay module  310  or separately. 
     An alternative network module  350 , illustrated in  FIG.  3 B , requires cable terminals  351   a,    351   b  (see  FIG.  5   ) for physically coupling the unswitched AUX cable  306  and the switched AUX cable  308  to a respective input and output of a relay module  360  comprising a plurality of relays. The network module  350  also requires the use of additional connections and wiring to mechanically and electrically couple the unswitched AUX cable  306  and the switched AUX cable  308  to the cable terminals  351   a,    351   b,  and to couple the cable terminals  351   a,    351   b  to the relay module  360 . In other embodiments, the relay module  360  may be external to the network module  350 , or internal to the network module  350  but with the connection terminal(s) to the switched AUX cable  308  external to the network module  350 . Similar to the network module  300 , the network module  350  includes a network controller  302  that controls the switching actions of the safety relay module  360  as defined by switching instructions received from a communications cable  304 . The network controller  302  of the network module  350  likewise comprises a processor or micro-controller, memory, input/output devices, required circuitry, and software. As illustrated in  FIG.  3 B , the communications cable  304  is coupled to the network controller  302  via a connection module  303   a,  which like the connection modules  303  discussed with respect to  FIG.  3 A  also comprises insulation displacement connection means. 
     While  FIG.  4    illustrates an exemplary connection module  303  utilizing insulation displacement means or connectors to make electrical contact with the wires of a profile (flat) cable,  FIG.  5    illustrates the use of a conventional cable terminal  351 . As discussed herein, the connection module  303  comprises contacts configured to pierce the insulative shield around a cable (e.g., a flat profile cable). When the connection module  303  is mechanically pressed against the cable, sharpened points of the contacts will be pressed into and through the insulative shielding to make electrical contact with the cable. As illustrated in  FIG.  5   , the wires of a profile cable have been exposed, stripped back, and landed onto respective terminals of the cable terminal  351 .  FIG.  5    illustrates a variety of cables landed on the terminals of the cable terminal  351  with a variety of jumper cables used to interconnect certain ones of the cables landed on the cable terminal  351 . 
       FIG.  6    illustrates an exemplary ASi network module  600  for a power switching module that includes the safety relay module  310  of  FIG.  3 A  and is configured to couple to an unswitched AUX cable  606  and a switched AUX cable  608 , where these cables ( 606 ,  608 ) are implemented as profile (flat) ASi cables. As illustrated in  FIG.  6   , an ASi communications cable  604  passes through the ASi network module  600 . The unswitched AUX cable  606  also passes through the ASi network module  600 , while the switched AUX cable  608  originates in the ASi network module  600  and extends outwardly from the ASi network module  600  (see  FIG.  6   ). The ASi network module  600  is configured to couple internal components (e.g., a controller/processor and relay module with relays, such as the network controller  302  and relay module  310  of  FIG.  3 A ) to respective ASi profile cables  604 ,  606 , and  608 . 
     Thus, the ASi network module  600  of  FIG.  6    illustrates an exemplary network module configured to control the passage of power from the unswitched AUX  606  cable to the switched AUX cable  608  (e.g., with the use of a controller and switching module, such as the network controller  302  and the safety relay module  310  of the network module  300 ). As discussed herein and like the network controller  302  of the network module  300 , the controller of the ASi network module  600  comprises, for example, a processor or micro-processor, a memory, input/output devices, required circuitry, and software. The ASi network module  600  of  FIG.  6    also includes M 12  network connectors  610  for coupling signals/power from the Asi profile cables to other external destinations via cables with M 12  network connectors. The network module  600  of  FIG.  6    also includes control/selector knobs  612 . For example, the network module  600  includes, for example, an address control/selector knob  612   b  and a selection knob  612   c.  Selector knob  612   a  may be utilized as a control or selector switch. 
       FIG.  7    illustrates a side view of an exemplary implementation of the Asi network module of  FIG.  6   . The Asi network module  700  of  FIG.  7    includes a facing portion  702  (that includes an arrangement of select/control knobs and M 12  network connectors, such as illustrated in  FIG.  6   ) and a back plate  703 . The Asi network module  700  is configured to couple internal components (e.g., a controller/processor and relay module, such as the network controller  302  and relay module  310  of  FIG.  3 A ) to respective ASi profile cables. In one embodiment, coupling the facing portion  702  to the back plate  703  engages insulation displacement connectors with respective profile cables arranged within the back plate  703  (see  FIG.  8   ). As illustrated in  FIG.  7   , the profile cables may be “keyed” (i.e., asymmetrically configured) such that they will fit within only certain matching ones of the openings  722  in the back plate  703 . Such arrangement of profile cables can be used to provide an assurance that an incoming or outgoing communication signal is communicatively coupled to the appropriate communication network cable (e.g., communications cables  604   a,    604   b ). Such arrangements may also be used to provide an assurance that the unswitched AUX cable  606  and the switched AUX cable  608  are placed within their proper openings  722  according to their polarity configurations. As illustrated in  FIG.  7   , a plurality of openings  722  are arranged in the back plate  703  of the ASi network module  700 . 
     The communications cables  604 , the unswitched AUX cable  606 , and the switched AUX cable  608  are illustrated in  FIG.  8    as portions of cabling, each with stripped wires extending from the ends of the cables. Such exemplary stripped wires are illustrated to demonstrate the orientation of the wires within their respective asymmetric profile cables. See  FIG.  4    for another illustration of the orientation of wires within a flat asymmetric profile cable. 
       FIG.  9    illustrates a perspective view of an exemplary implementation of the ASi network module of  FIG.  6   . The ASi network module  900  of  FIG.  9    includes a set of M 12  network connectors  910  and control/select knobs  912  on a front surface of a facing portion  902  and a set of openings  922  arranged on the sides (of a back plate  903 ) for receiving and passing through asymmetric ASi profile (flat) cables. Note that the openings  922  are keyed such that the asymmetric cable is only received in a required orientation for proper polarity configurations (see  FIG.  10   ). The ASi network module  900  is configured to couple internal components (e.g., a controller and relay module, such as the network controller  302  and relay module  310  of  FIG.  3 A ) to respective ASi profile cables. As discussed herein, and like the network controller  302  of the network module  300 , the controller of the ASi network module  900  comprises, for example, a processor or micro-processor, a memory, input/output devices, required circuitry, and software. 
       FIG.  10    illustrates an interior view of the back plate  903  of the ASi network module  900  of  FIG.  9   , illustrating the placement arrangement of flat profile cables in the ASi network module  900 . Note that because the exemplary ASi network cables are asymmetric profile cables, the cables will be running in only one direction for proper polarity configurations (e.g., there are two separate communications profile cables, each running in a different direction). 
     Thus, embodiments of the exemplary network module are configured to receive network cables (e.g., ASi profile network cables) and to couple to them using insulation displacement connections. That is, network cables may be utilized that allow for insulation displacement connections. The network module is configured to provide switched auxiliary (AUX) power for E-stop system functionality in a network system. The network module receives at least one communications cable and an unswitched AUX cable, as well as originating a switched AUX cable. The network module includes a controller and a switching module. The controller is configured to control the passage of power through the switched AUX cable by controlling the passage of power from the unswitched AUX cable to the switched AUX cable (via the switching module, which is coupled to interconnect power from the unswitched AUX cable to the switched AUX cable). The switching module is configured to control the passage of power through the switched AUX cable via control signals received from the controller. The exemplary insulation displacement connectors allow for an efficient coupling of signals/power to internal components without requiring the additional hardware and wiring needed to physically land the network cables in the network module. 
     Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the present invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.