Patent Description:
An industrial automation system may be used to provide automated control of one or more actuators. For example, a controller of the industrial automation system may output a conditioned power signal to an actuator to control movement of the actuator. Input/output (I/O) components may facilitate communication between the controller and the actuator or other devices within the industrial automation system. In certain industrial automation systems, redundant I/O components may be utilized to maintain communication between the controller and the actuator or the other devices. However, maintenance of the redundant I/O components may require removal of a particular I/O component in a pair of redundant I/O components and insertion of a replacement I/O component. Such maintenance may disrupt the communication between the controller and the actuator or the other devices. Thus, it may be desirable to facilitate maintenance or replacement of redundant I/O components in an industrial automation system such that disruption of communication between a controller and other devices in the industrial automation system is minimized.

<CIT> relates to a system which includes a triple modular redundant (TMR) control system comprising three controllers. Each controller of the three controllers includes a current driver system configured to detect and regulate a portion of a total current output of the TMR control system, and a universal input-output (UIO) system comprising a plurality of universal input-output (UIO) ports, wherein the universal input-output (UIO) system is configured to detect the portion of the total current output and the total current output of the TMR control system via one or more of the plurality of the UIO ports, compare the portion of the current output and the total current output of the TMR control system, and adjust the portion of the total current output according to a predetermined total current output threshold. <NPL>, this document discusses a redundant I/O platform, which offers ease of use. In particular, the I/O platform supports both simplex and duplex configurations. <CIT> discusses a fault tolerant computer system and method. The system may include a plurality of CPU nodes, each including: a processor and a memory; at least two IO domains, wherein at least one of the IO domains is designated an active IO domain performing communication functions for the active CPU nodes; and a switching fabric connecting each CPU node to each IO domain. One CPU node is designated a standby CPU node and the remainder are designated as active CPU nodes. If a failure, a beginning of a failure, or a predicted failure occurs in an active node, the state and memory of the active CPU node are transferred to the standby CPU node which becomes the new active CPU node. If a failure occurs in an active IO domain, the communication functions performed by the failing active IO domain are transferred to the other IO domain. It is the object of the present invention to enable disruption free operation of an industrial automation system.

In one embodiment, an input/output (I/O) system of an industrial automation system is provided according to claim <NUM>.

In another embodiment, a method is provided according to claim <NUM>.

In yet another embodiment, a non-transitory, computer-readable medium is provided according to claim <NUM>.

As mentioned above, redundant I/O components within an industrial automation system may be utilized to maintain communication with and control of one or more devices by a connection originator (e.g., a controller) in the industrial automation system. However, maintenance of the redundant I/O components may require removal of a particular I/O component in a pair of redundant I/O components and/or insertion of a replacement I/O component. Such maintenance may disrupt control of the operation of the devices by the connection originator.

Accordingly, embodiments of the present disclosure are generally directed to seamlessly switching between different modes of operation associated with partner I/O channels associated with a pair of redundant I/O components in an industrial automation system in a seamless (e.g., bumpless) manner. For example, each redundant I/O component of the pair of redundant I/O components may include one or more isolated channels. Each isolated channel in a first redundant I/O component of the pair of redundant I/O components has a partner isolated channel in a second redundant I/O component of the pair of redundant I/O components. Each pair of partner isolated channels between the pair of redundant I/O components typically operate in a duplex mode of operation such that each pair of partner isolated channels coordinate performance of a particular operation to maintain communication with or control of a respective device by the connection originator in the industrial system. However, if a fault occurs on a first channel of the pair of partner isolated channels, the second channel of the pair of partner isolated channels that did not experience the fault may switch to a suplex mode of operation (e.g., a single duplex mode of operation) such that the second channel performs the particular operation without coordinating with the first channel. In this way, the second channel may take over full performance of the operation while the first channel undergoes maintenance. Additionally, because each channel in each redundant I/O component is isolated from one another, other pairs of partner isolated channels between the pair of redundant I/O components may continue to operate in the duplex mode of operation.

Further, maintenance of the redundant I/O component with the faulty channel (e.g., the first redundant I/O component of the pair of redundant I/O components) may require removal of the first redundant I/O component from the industrial automation system. For example, a maintenance technician may unlock the first redundant I/O component from a base (e.g., a removable terminal block) in the industrial automation system via an actuator in order to remove the first redundant I/O component. After receiving an indication that the first redundant I/O component is being removed from the base but before the first redundant I/O component has been physically removed from the base, the first redundant I/O component may initiate a reconfiguration process associated with the other pairs of partner isolated channels among the pair of redundant I/O components In particular, the isolated channels of each pair of partner isolated channels associated with the second redundant I/O component may switch their respective modes of operation to the suplex mode of operation such that the isolated channels of the second redundant I/O component perform their respective operations without coordinating with their respective partner channels in the first redundant I/O component. In this way, the reconfiguration process may facilitate a seamless (e.g., bumpless) transition between the duplex mode of operation to the suplex mode of operation of each isolated channel of the second redundant I/O component such that any disruption in the communication with or control of devices in the industrial automation system by the connection originator is minimized when removing the first redundant I/O component from the industrial automation system.

As mentioned above, a maintenance technician may insert a third I/O component (e.g., a replacement I/O component) into the base (e.g., a removable terminal block) to replace the first redundant I/O component in the pair of redundant I/O components. For example, after receiving an indication that the replacement redundant I/O component is being inserted into the base, the replacement redundant I/O component may initiate a second reconfiguration process associated with each pair of partner isolated channels between the replacement redundant I/O component and the second redundant I/O component. In particular, the isolated channels of each pair of partner isolated channels between with the replacement redundant I/O component and the second redundant I/O component may switch to a duplex mode of operation such that each pair of partner i solated channels coordinate performance of a particular operation to maintain communication with or control of a respective device by the connection originator in the industrial system. In this way, the second reconfiguration process may facilitate a seamless (e.g., bumpless) transition between the suplex mode of operation of each isolated channel of the second redundant I/O component to the duplex mode of operation of each pair of partner isolated channels between the second redundant I/O component and the replacement redundant I/O component when inserting the replacement I/O component into the industrial automation system.

By way of introduction, <FIG> is a schematic view of an industrial automation system <NUM>. As shown, the industrial automation system <NUM> includes a controller <NUM> (i.e., a connection originator) and an actuator <NUM> (e.g., a motor). The industrial automation system <NUM> may also include, or be coupled to, a power source <NUM>. The power source <NUM> may include a generator, a battery (or other power storage device), or an external power grid. Though the controller <NUM> shown in <FIG> is a stand-alone controller <NUM>, in more complex industrial automation systems <NUM>, one or more controllers <NUM> may be grouped together with other components in a motor control center (MCC) to control multiple actuators. In the instant embodiment, the controller <NUM> includes a user interface <NUM>, such as a human machine interface (HMI), and a control system <NUM>, which may include a memory <NUM> and a processor <NUM>.

The control system <NUM> may be programmed (e.g., via computer readable code or instructions stored on the memory <NUM> and configured to be executed by the processor <NUM>) to provide signals for driving the motor <NUM>. In certain embodiments, the control system <NUM> may be programmed according to a specific configuration desired for a particular application. For example, the control system <NUM> may be programmed to respond to external inputs, such as reference signals, alarms, command/status signals, etc. The external inputs may originate from one or more relays or other electronic devices (such as sensors <NUM>). The programming of the control system <NUM> may be accomplished through software configuration or firmware code that may be loaded onto the internal memory <NUM> of the control system <NUM> or programmed via the user interface <NUM> of the controller <NUM>. The control system <NUM> may respond to a defined set of operating parameters. The settings of the various operating parameters determine the operating characteristics of the controller <NUM>. For example, various operating parameters may determine the speed or torque of the motor <NUM> or may determine how the controller <NUM> responds to the various external inputs (such as from sensors <NUM>). As such, the operating parameters may be used to map control variables within the controller <NUM> or to control other devices communicatively coupled to the controller <NUM>. These variables may include, for example, speed presets, feedback types and values, computational gains and variables, algorithm adjustments, status and feedback variables, programmable logic controller (PLC) like control programming, and the like.

In some embodiments, the controller <NUM> may be communicatively coupled to one or more sensors <NUM> for detecting operating temperatures, voltages, currents, pressures, flow rates, etc. within the industrial automation system <NUM>. With feedback data from the sensors <NUM>, the control system <NUM> may keep detailed track of the various conditions under which the industrial automation system <NUM> may be operating. For example, the feedback data may include conditions such as actual motor speed, voltage, frequency, power quality, alarm conditions, etc..

<FIG> is a schematic view of a modular input/output (I/O) system <NUM> for the industrial automation system <NUM> shown in <FIG>. As illustrated, the modular I/O system <NUM> includes a network adapter <NUM> that is in communication with a controller <NUM> (i.e., a connection originator) via a network <NUM> (e.g., an Ethernet/IP network or other industrial automation network) such that the network adapter <NUM> receives data from, transmits data to, and otherwise communicates with the controller <NUM>. For example, the controller <NUM> may be a programmable logic controller or a PLC. The network adapter <NUM> includes a network adapter base <NUM>, a network adapter component <NUM> (e.g., a network adapter module), a network connector <NUM>, and a power connector <NUM>. In some embodiments, the network adapter <NUM> may also include power conditioning circuitry <NUM>. The network adapter base <NUM> may be mounted (e.g., permanently or removably coupled) to a rail or plate <NUM>. The network adapter component <NUM> may be removably coupled to the network adapter base <NUM> and include communication circuitry for communication with the controller <NUM> via the network connector <NUM> and the network <NUM> and/or communication with other I/O banks <NUM> coupled to the rail or panel <NUM>. As such, the network adapter component <NUM> may be configured to manage communication within the I/O system (e.g., between the network adapter <NUM> and the various other I/O banks <NUM>), and/or between the I/O system <NUM> and various other components of the industrial automation system including, for example, the controller <NUM>. The power connector <NUM> may be configured to receive power from a power source (which may or may not be the same power source <NUM> shown in <FIG>) that supplies power to the network adapter <NUM> and one or more other I/O banks <NUM> coupled to the rail or panel <NUM>. In embodiments that have power conditioning circuitry <NUM>, the power conditioning circuitry <NUM> may be configured to condition the power received from the power source <NUM> via the power connector <NUM> by amplifying the power signal, attenuating the power signal, stepping the power signal up or down, inverting the power signal, applying one or more filters to the power signal, converting a direct current (DC) power signal to alternating current (AC) power, converting an AC power signal to DC power, and so forth.

Each of the one or more other I/O banks <NUM> may include an I/O base <NUM>, one or more I/O components <NUM>, <NUM> (e.g., an I/O module), and a terminal block <NUM> (e.g., removable terminal block or "RTB"). The I/O base <NUM> may also be mounted (e.g., permanently or removably coupled) to the rail or panel <NUM>. The other I/O banks <NUM> may be sequentially communicatively coupled to one another and to the network adapter <NUM> via a multi-contact connector <NUM>, forming a backplane <NUM>, and enabling communication with the controller <NUM> and one or more other I/O devices <NUM> via the I/O wiring <NUM>. The I/O components <NUM>, <NUM> may be removably coupled to the I/O base <NUM> (e.g., via the terminal block <NUM>), thus enabling communication between the I/O components <NUM>, <NUM> and the controller <NUM> via the network adapter <NUM> and the backplane <NUM>.

The I/O components <NUM>, <NUM> may be configured to perform one or more specialized industrial automation input/output functions such as DC input, DC output, AC input, AC output, analog input and/or output, resistance temperature detector (RTD) and/or thermocouple input, an output signal to control an actuator, and so forth. For example, the I/O components <NUM>, <NUM> may facilitate communication with or control of one or more I/O devices <NUM> by the controller <NUM>. As illustrated in <FIG>, the I/O components <NUM>, <NUM> may operate as a redundant pair of I/O components <NUM>, <NUM>. For example, each I/O component <NUM>, <NUM> may include one or more isolated channels that has a respective partner isolated channel in the other I/O component <NUM>, <NUM>. Each pair of partner isolated channels between the pair of I/O components may operate either in a duplex mode of operation or a single duplex (i.e., "suplex") mode of operation. In the duplex mode of operation, one or more pairs of partner isolated channels between the I/O components <NUM>, <NUM> may coordinate to perform one or more respective specialized industrial automation input/output operations. In the suplex mode of operation, one or more isolated channels in each I/O component <NUM>, <NUM> may perform the respective specialized industrial automation input/output operations without coordinating with a partner isolated channel. Additional details regarding the operation of the isolated channels in the I/O components <NUM>, <NUM> are discussed herein with respect to <FIG>.

Referring back to <FIG>, the terminal blocks <NUM> may include cage clamps, spring clamps, push-in terminals, screw terminals, or other wiring connectors <NUM> configured to couple to field wires associated with a field I/O device <NUM> (e.g., a sensor, flow meter, switch, probe, thermocouple, RTD, encoder, actuator, and so forth) associated with a process or machine being controlled by the controller <NUM>. In some embodiments, the terminal block <NUM> may be a separate structure that is assembled and coupled to the I/O base <NUM>. In other embodiments, the terminal block <NUM> may be integral to the I/O base <NUM>. Different embodiments/configurations of terminal blocks <NUM> may be utilized, depending upon the particular configuration suited for the field device wiring connectors <NUM> (e.g., having different common terminals, ground connections, voltage supply terminals, etc.). The I/O banks <NUM> of terminal block <NUM> may also include a power connector <NUM> to receive power from a power source (which may or may not be the same power source <NUM> shown in <FIG>) that supplies power to the I/O bank <NUM> and/or the I/O devices <NUM> (e.g., sensors, actuators, etc.) that are communicatively coupled to the I/O bank <NUM>. Each installed I/O component <NUM>, <NUM> communicates with the field device wiring connectors <NUM> of the same I/O base <NUM> to which the I/O component <NUM>, <NUM> is physically coupled (e.g., via the terminal block <NUM>). Input/output data is provided between the controller <NUM> and the I/O devices <NUM> connected to the corresponding I/O base <NUM> via the backplane <NUM>, the network adapter component <NUM>, and the I/O components <NUM>, <NUM>. In some embodiments, the network adapter <NUM> and I/O banks <NUM> may be coupled to the rail or panel <NUM> via respective backplane switches <NUM>, sometimes called bus interface modules (BIMs), that facilitate electrical connections between the various components of the backplane switch <NUM> (e. g, the network adapter <NUM>, the I/O banks <NUM>, the rail <NUM>, etc.). In some embodiments, the multi-contact connector <NUM> and the backplane switch <NUM> may be distinct components. In other embodiments, the functions of the multi-contact connector <NUM> and the backplane switch <NUM> may be performed by the same component.

As shown in <FIG>, the backplane <NUM> is a circuit that sequentially couples the network adapter <NUM> and the adjacent I/O banks <NUM> in a series or a sequential manner through the connectors <NUM> of the backplane <NUM> and/or the backplane switch <NUM>. For example, the backplane switches <NUM> of the adapter <NUM> and each I/O bank <NUM> use backplane data communication protocols to establish the above-described backplane circuit <NUM>.

With the foregoing in mind, <FIG> is a block diagram <NUM> that illustrates a reconfiguration process associated with a pair of redundant I/O components <NUM>, <NUM> after a first redundant I/O component <NUM> of the pair of redundant I/O components experiences a fault. As mentioned above, the pair of redundant I/O components <NUM>, <NUM> may facilitate communication with or control of one or more I/O devices <NUM> by a connection originator (e.g., the controller <NUM>) in the industrial automation system <NUM>. For example, the first redundant I/O component <NUM> of the pair of redundant I/O components <NUM>, <NUM> may include isolated channels <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> while the second redundant I/O component <NUM> of the pair of redundant I/O components <NUM>, <NUM> may include isolated channels <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. Although <FIG> illustrates that each redundant I/O component <NUM>, <NUM> includes eight isolated channels, it should be understood that, in other embodiments, each redundant I/O component <NUM>, <NUM> may have any suitable number of isolated channels. In any case, each isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in the first redundant I/O component <NUM> has a partner isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in the second redundant I/O component <NUM>. As illustrated in <FIG>, for example, isolated channel <NUM> of the first redundant I/O component <NUM> and isolated channel <NUM> of the second redundant I/O component <NUM> are partner isolated channels, isolated channel <NUM> of the first redundant I/O component <NUM> and isolated channel <NUM> of the second redundant I/O component <NUM> are partner isolated channels, and so on and so forth.

As illustrated in box 200A of <FIG>, each pair of partner isolated channels (e.g., <NUM> and <NUM>) between the first redundant I/O component <NUM> and the second redundant I/O component <NUM> may operate under a duplex mode of operation to perform a specialized industrial automation input/output operation. Box 200A may correspond to a "normal" state of the pair of redundant I/O components <NUM>, <NUM> in the industrial automation system <NUM>. For instance, the pair of redundant I/O components <NUM>, <NUM> may operate under a "normal" state when none of the isolated channels (e.g., <NUM>, <NUM>) of the pair of redundant I/O components <NUM>, <NUM> have experienced a fault.

In certain embodiments, under the duplex mode of operation, the controller <NUM> may transmit a command to an I/O device <NUM> in the industrial automation system <NUM> via the network adapter <NUM> and the redundant I/O components <NUM>, <NUM>. In particular, the network adapter <NUM> may receive the command from the controller <NUM> and relay the command to both redundant I/O components <NUM>, <NUM>. After each redundant I/O component <NUM>, <NUM> receives a respective command from the network adapter <NUM>, a pair of partner isolated channels (e.g., <NUM>, <NUM>) between the redundant I/O components <NUM>, <NUM> may coordinate operation to perform a specialized industrial automation input/output operation that facilitates performance of the command by the I/O device <NUM>. For instance, each partner isolated channel (e.g., <NUM>, <NUM>) may transmit an output signal to the I/O device <NUM> indicative of the command.

Additionally, or alternatively, the pair of partner isolated channels (e.g., <NUM>, <NUM>) between the redundant I/O components <NUM>, <NUM> may communicate input data (e.g., sensor data) from the I/O device <NUM> to the controller <NUM> via the network adapter <NUM>. For example, each partner isolated channels (e.g., <NUM>, <NUM>) may receive (e.g., listen for) input data from the I/O device <NUM> and communicate with each other to compare corresponding values within the received input data received by each partner isolated channel (e.g., <NUM>, <NUM>). After the pair of partner isolated channels (e.g., <NUM>, <NUM>) agree on a value to send to the network adapter <NUM>, each partner isolated channel (e.g., <NUM>, <NUM>) of the redundant I/O components <NUM>, <NUM> transmits a signal to the network adapter <NUM> indicative of the agreed upon value. The network adapter <NUM> may then transmit a signal indicative of the received value to the controller <NUM>.

As mentioned above, during operation of each pair of partner isolated channels (e.g., <NUM>, <NUM>) between the redundant I/O components <NUM>, <NUM>, a particular isolated channel (e.g., <NUM>) may experience a fault or otherwise becomes disengaged. For example, an isolated channel may experience a fault due to loss of power, an overload of power, a short in a circuit, a firmware error, or the like. In certain embodiments, the isolated channel may become disengaged if the isolated channel does not have a configuration or the isolated channel has a conflicting configuration with the configuration of its partner isolated channel As illustrated in box 200B of <FIG>, in response to the fault experienced by the isolated channel <NUM> of the redundant I/O component <NUM>, the partner isolated channel <NUM> in the redundant I/O component <NUM> may switch to a suplex mode of operation such that the isolated channel <NUM> in the redundant I/O component performs a specialized industrial automation input/output operation without coordinating with the isolated channel <NUM> that experienced the fault. In certain embodiments, the isolated channel <NUM> in the redundant I/O component <NUM> may receive a signal indicative of the fault in the isolated channel <NUM> from the isolated channel <NUM> and/or the redundant I/O component <NUM>. After receiving the signal, the isolated channel <NUM> may reconfigure itself to function in the suplex mode of operation. As mentioned above, the specialized industrial automation input/output operation may facilitate communication between or control of a I/O device (e.g., <NUM>) by the controller <NUM>. Additionally, because each partner isolated channel (e.g., <NUM> and <NUM>, <NUM> and <NUM>) in each redundant I/O component <NUM>, <NUM> is isolated from one another, the other pairs of isolated channels between the pair of redundant I/O components <NUM>, <NUM> may continue to operate in the duplex mode of operation.

Thereafter, a maintenance technician may remove the redundant I/O component <NUM> with the faulty isolated channel <NUM> during maintenance of the redundant I/O component <NUM>. As illustrated in box 200C of <FIG>, each redundant I/O component <NUM>, <NUM> may include an actuator <NUM>, <NUM> that allows a maintenance technician to unlock the corresponding redundant I/O component <NUM>, <NUM> from the terminal block <NUM> or lock the corresponding redundant I/O component <NUM>, <NUM> into the terminal block <NUM>. In certain embodiments, the maintenance technician may rotate the actuator <NUM>, <NUM> one-quarter turn to lock or unlock the corresponding redundant I/O component <NUM>, <NUM> with respect to the terminal block <NUM>. However, it should be noted that, in other embodiments, any other suitable locking mechanism may be utilized to secure the redundant I/O components <NUM>, <NUM> to the terminal block <NUM>. For example, in some embodiments, a locking tab may be utilized to allow a redundant I/O component <NUM>, <NUM> to be snap fit to the terminal block <NUM> or released from the terminal block 124after disengagement of the locking tab.

In any case, as the maintenance technician begins to unlock the redundant I/O component <NUM> with the fault channel <NUM> from the terminal block <NUM>, the redundant I/O component <NUM> may receive a signal indicative of the redundant I/O component being unlocked from the actuator <NUM>. In some embodiments, the actuator <NUM> may be communicatively coupled to a sensor that continuously or intermittently generates a signal indicative of whether the actuator <NUM> is a locked or unlocked position. After receiving the signal indicative of the redundant <NUM>/O component <NUM> being unlocked from the actuator <NUM>, the redundant I/O component <NUM> may trigger a reconfiguration process to switch the remaining isolated channels (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) of the redundant I/O component <NUM> into the suplex mode of operation before the redundant I/O component <NUM> is removed from the terminal block <NUM>.

In certain embodiments, under the suplex mode of operation, the controller <NUM> may transmit a command to an I/O device in the industrial automation system <NUM> via the network adapter <NUM> and the redundant I/O component <NUM>. In particular, after receiving the command from the controller <NUM>, the network adapter <NUM> may relay the command to the redundant I/O component <NUM> with the faulty channel <NUM> and the redundant I/O component <NUM>. After the redundant I/O component <NUM> receives the command from the network adapter <NUM>, an isolated channel (e.g., <NUM>) of the redundant I/O component <NUM> may perform a specialized industrial automation input/output operation that facilitates performance of the command by the I/O device <NUM>. Although the redundant I/O component <NUM> with the faulty channel <NUM> receives the command from the network adapter <NUM>, the faulty channel (e.g., <NUM>) of the redundant I/O component <NUM> does not coordinate performance of the specialized industrial automation input/output operation with the isolated channel (e.g., <NUM>) of the redundant I/O component <NUM> because the isolated channel (e.g., <NUM>) is operating in the suplex mode of operation. That is, the redundant I/O component <NUM> may still receive commands from the network adapter <NUM> to perform specialized industrial automation input/output operations via the faulty channel <NUM> but the redundant I/O component <NUM> does not perform the specialized industrial automation input/output operations.

Additionally, or alternatively, the isolated channel (e.g., <NUM>) of the redundant I/O components <NUM> may communicate input data (e.g., sensor data) from the I/O device <NUM> to the controller <NUM> via the network adapter <NUM>. For example, the isolated channel (e.g., <NUM>) may receive (e.g., listen for) input data from the I/O device <NUM> and transmit a signal indicative of one or more values of the input data to the network adapter <NUM> without communicating with the redundant I/O component <NUM> with the faulty channel <NUM>. The network adapter <NUM> may then transmit a signal indicative of the received values to the controller <NUM>.

After the reconfiguration process of the redundant I/O component <NUM> completes, the redundant I/O component <NUM> with the faulty channel <NUM> may disengage from the terminal block <NUM>. For example, the redundant I/O component <NUM> may physically decouple from one or more terminals associated with the terminal block 124such that the redundant I/O component <NUM> is no longer communicating with the network adapter <NUM> or a corresponding I/O device <NUM>. In this way, the reconfiguration process may facilitate a seamless (e.g., bumpless) transition between the duplex mode of operation by each pair of partner isolated channels (e.g., <NUM>, <NUM>) between the pair of redundant I/O components <NUM>, <NUM> to the suplex mode of operation by each isolated channel (e.g., <NUM>) in the redundant I/O component <NUM> not being removed by the technician. As referred to herein, a "bumpless" transition refers to the duration of the reconfiguration process being less than five milliseconds (ms) or the controller <NUM> not experiencing a loss of communication with the I/O device <NUM>. Additional details regarding the reconfiguration process are described below with respect to <FIG>. Thereafter, the maintenance technician may remove the redundant I/O component <NUM> with the faulty channel <NUM> after the reconfiguration process is complete. As illustrated in box 200D of <FIG>, the redundant I/O component <NUM> with the faulty channel <NUM> has been removed from the terminal block <NUM>, and the redundant I/O component <NUM> (e.g., each isolated channel of the redundant I/O component <NUM>) is operating in the suplex mode of operation.

With the foregoing in mind, <FIG> illustrates a flowchart of a method <NUM> for coordinating disengagement of the redundant I/O component <NUM> that has the faulty channel <NUM> and reconfiguration of one or more isolated channels (e.g., <NUM>) of the redundant I/O component <NUM> from a duplex mode of operation to a suplex mode of operation. For example, the method <NUM> may be performed by the pair of redundant I/O components <NUM>, <NUM> after the redundant I/O component <NUM> with the faulty channel <NUM> has received a signal indicative of its removal from the terminal block 124but before the redundant I/O component <NUM> has physically been removed from the terminal block <NUM>. In this way, the method <NUM> facilitates a seamless or bumpless transition in the operation of the pair of redundant I/O components <NUM>, <NUM> from the duplex mode of operation to the suplex mode of operation (e.g., by the redundant I/O component <NUM>). Although the following description of the method <NUM> is described in a particular order, it should be noted that the method <NUM> is not limited to the depicted order, and instead, the method <NUM> may be performed in any suitable order. Moreover, although certain blocks of the method <NUM> are described as being performed by the redundant I/O component <NUM>, it should be noted that such steps may be performed by the redundant I/O component <NUM> if the redundant <NUM>/O component <NUM> has one or more faulty channels and/or is being removed from the terminal block <NUM>. Similarly, although certain blocks of the method <NUM> are described as being performed by the redundant I/O component <NUM>, it should be noted that such steps may be performed by the redundant I/O component <NUM> if the redundant I/O component <NUM> has one or more faulty channels and/or is being removed from the terminal block <NUM>.

Referring now to <FIG>, at block <NUM>, the redundant I/O component <NUM> with the faulty channel <NUM> may receive a signal indicative of the redundant I/O component <NUM> being unlocked from the terminal block <NUM>. In certain embodiments, a maintenance technician may turn an actuator <NUM> associated with the redundant I/O component <NUM> from a locked position (e.g., the position of actuator <NUM> in <FIG>) to an unlocked position (e.g., the position of actuator <NUM> in <FIG>). A sensor associated with the actuator <NUM> may transmit the signal indicative of the redundant I/O component <NUM> being unlocked from the terminal block 124to the redundant I/O component <NUM>. For instance, the redundant I/O component <NUM> may include a sensor that detects the position of the actuator <NUM>, the terminal block 124may include a sensor that detects the position of the actuator <NUM>, or both. After receiving the signal indicative of the redundant I/O component <NUM> being unlocked from the terminal block <NUM>, at block <NUM>, the redundant I/O component <NUM> may generate a schedule for completing a disengagement procedure that disengages or decouples the redundant <NUM>/O component <NUM> from one or more terminals associated with the terminal block <NUM>. For example, the redundant I/O component <NUM> may select a particular time or a particular period of time in which to begin the disengagement procedure. The redundant I/O component <NUM> may then transmit or push the schedule for the disengagement procedure to the redundant I/O component <NUM> without the faulty channel <NUM>.

After receiving the schedule for the disengagement procedure, at block <NUM>, the redundant I/O component <NUM> may determine whether the schedule for the disengagement procedure does not conflict with its own schedule for performing one or more operations. For instance, the redundant I/O component <NUM> may have one or more diagnostic operations scheduled to be performed at a particular time. If the redundant I/O component <NUM> determines that the schedule for the disengagement procedure does not conflict with its own schedule for performing one or more operations, the redundant I/O component <NUM> may accept the received schedule for the disengagement procedure at block <NUM>. For example, the redundant I/O component <NUM> may transmit a signal or a message indicative of the acceptance to the redundant I/O component <NUM>. However, if the redundant I/O component <NUM> determines that the schedule for the disengagement procedure conflicts with its own schedule for performing one or more operations, the redundant I/O component <NUM> may generate a new schedule for completing the disengagement procedure and transmit the new schedule to the redundant I/O component <NUM> at block <NUM>. At block <NUM>, after receiving the new schedule from the redundant I/O component <NUM>, the redundant I/O component <NUM> may accept the new schedule. For example, the redundant I/O component <NUM> may transmit a signal or a message indicative of the acceptance to the redundant I/O component <NUM>.

After the redundant I/O component <NUM> accepts the schedule for disengagement at block <NUM> or the redundant I/O component <NUM> accepts the schedule for disengagement at block <NUM>, the pair of redundant I/O components <NUM>, <NUM> may proceed to perform the disengagement procedure associated with the redundant I/O component <NUM> and the reconfiguration procedure associated with the redundant I/O component <NUM> at block <NUM>. That is, at the scheduled time, the redundant I/O component <NUM> that has been unlocked from the terminal block 124may perform the disengagement procedure and the redundant I/O component <NUM> may perform a reconfiguration procedure to switch each isolated channel of the redundant I/O component <NUM> from a duplex mode of operation to a suplex mode of operation.

In certain embodiments, the reconfiguration procedure associated with the redundant I/O component <NUM> may be performed before the disengagement procedure associated with the redundant I/O component <NUM>. For example, after each isolated channel (e.g., <NUM>) of the redundant I/O component <NUM> switches to the suplex mode of operation, the redundant I/O component <NUM> may transmit state or configuration data associated with the redundant I/O component <NUM> to the redundant I/O component <NUM>. In certain embodiments, the state or configuration data may include Highway Addressable Remote Transducer (HART) state data. Based on the received state or configuration data, the redundant I/O component <NUM> may determine that the redundant I/O component <NUM> has taken over control of performing any specialized industrial automation input/output operations to facilitate communication with or control of the I/O device <NUM>. The redundant I/O component <NUM> may then disengage or decouple from one or more terminals associated with the terminal block <NUM>. After the redundant I/O component <NUM> has disengaged from the terminals, the redundant I/O component <NUM> may transmit state or configuration data associated with the redundant I/O component <NUM> to the redundant I/O component <NUM>. In certain embodiments, the state or configuration data may include Highway HART state data. The state or configuration data may be utilized by the redundant I/O component <NUM> to perform one or more specialized industrial automation input/output operations.

After the disengagement procedure associated with the redundant I/O component <NUM> and the reconfiguration procedure associated with the redundant I/O component <NUM> has completed at block <NUM>, the redundant I/O component <NUM> may provide an indication that the redundant I/O component <NUM> may be removed from the terminal block <NUM> In certain embodiments, the redundant I/O component <NUM> may display an indication via a display screen that the redundant I/O component <NUM> may be removed or cause a light or any other suitable indicator associated with the redundant I/O component <NUM> to indicate that the redundant I/O component <NUM> may be removed. In any case, thereafter, the maintenance technician may remove the redundant I/O component <NUM> from the terminal block 124leaving the redundant I/O component <NUM> to operate under the suplex mode of operation.

As mentioned above, the maintenance technician may replace the redundant I/O component <NUM> that has a faulty channel <NUM> with a replacement I/O component. For example, the maintenance technician may insert the replacement I/O component into the terminal block 124to pair the replacement component I/O component with the redundant I/O component <NUM>). With the forgoing in mind, <FIG> is a block diagram <NUM> that illustrates a reconfiguration process associated with the redundant I/O component <NUM> and a replacement I/O component <NUM> that has been inserted into the terminal block <NUM>. As illustrated in box 300A of <FIG>, the redundant I/O component <NUM> is operating under a suplex mode of operation to perform one or more specialized industrial automation input/output operations. That is, each isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in the redundant I/O component <NUM> is operating under the suplex mode of operation. The replacement I/O component <NUM> may be inserted into the terminal block 124such that each isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the replacement I/O component <NUM> is disengaged from the terminals of the terminal block <NUM>.

After the replacement I/O component <NUM> has been inserted into the terminal block <NUM>, the replacement I/O component <NUM> and the redundant I/O component <NUM> may perform a pairing process. For example, the replacement I/O component <NUM> and the redundant I/O component <NUM> may perform the pairing process after the maintenance technician has locked the replacement I/O component <NUM> into the terminal block <NUM>. In certain embodiments, the maintenance technician may rotate an actuator <NUM> associated with the replacement I/O component <NUM> one-quarter turn to lock or unlock the replacement I/O component <NUM> with respect to the terminal block <NUM>. However, it should be noted that, in other embodiments, any other suitable locking mechanism may be utilized to secure the replacement I/O component <NUM> to the terminal block <NUM>. Additional details with regard to the pairing process performed by the replacement I/O component <NUM> and the redundant I/O component <NUM> are described below with respect to <FIG>.

After the replacement I/O component <NUM> and the redundant I/O component <NUM> have been paired, the replacement I/O component <NUM> and the redundant I/O component <NUM> may switch to the duplex mode of operation to coordinate the performance of one or more specialized industrial automation input/output operations. As illustrated in box 300B in <FIG>, each isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in the replacement I/O component <NUM> and each isolated channel <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in the redundant I/O component <NUM> is operating under the duplex mode of operation. That is, each pair of isolated channels between the replacement I/O component <NUM> and the redundant I/O component <NUM> may coordinate operation to perform one or more specialized industrial automation input/output operations to facilitate communication between or control of the I/O device <NUM> by the controller <NUM>.

With the foregoing in mind, <FIG> illustrates a flowchart of a method <NUM> for pairing the replacement I/O component <NUM> with the redundant I/O component <NUM> after the replacement I/O component <NUM> has been inserted into the terminal block <NUM>. Although the following description of the method <NUM> is described in a particular order, it should be noted that the method <NUM> is not limited to the depicted order, and instead, the method <NUM> may be performed in any suitable order. Referring now to <FIG>, at block <NUM>, the replacement I/O component <NUM> may detect the presence of the redundant I/O component <NUM> and/or the redundant I/O component <NUM> may detect the presence of the replacement I/O component <NUM>. In certain embodiments, the replacement I/O component <NUM> may broadcast a signal indicative of the presence of the replacement I/O component <NUM> in the terminal block <NUM> in an area surrounding the replacement I/O component <NUM>, the redundant I/O component <NUM> may broadcast a signal indicative of the presence of the redundant I/O component <NUM> in an area surrounding the redundant I/O component <NUM>, or both. For example, each I/O component <NUM>, <NUM> may broadcast the respective signals at a frequency greater than a scan rate of the I/O components <NUM>, <NUM> or any other suitable rate.

After the replacement I/O component <NUM> detects the presence of the redundant I/O component <NUM> and/or the redundant I/O component <NUM> detects the replacement component <NUM> at block <NUM>, the replacement I/O component <NUM> may verify hardware and software compatibility with the redundant I/O component <NUM> and/or the redundant I/O component <NUM> may verify hardware and software compatibility with the replacement I/O component <NUM>. If the redundant I/O component <NUM> determines that the replacement I/O component <NUM> is not hardware and/or software compatible and/or the replacement I/O component <NUM> determines that the redundant I/O component <NUM> is not hardware and/or software compatible, at block <NUM>, the replacement I/O component <NUM> may provide an indication of the hardware and/or software incompatibility. For example, the replacement I/O component <NUM> may provide the indication via a display, an LED, or the like.

However, if the redundant I/O component <NUM> determines that the replacement I/O component <NUM> is hardware and/or software compatible and/or the replacement I/O component <NUM> determines that the redundant I/O component <NUM> is hardware and/or software compatible, at block <NUM>, the replacement I/O component <NUM> may receive a connection request from the controller <NUM> (i.e., the connection originator). For instance, the controller <NUM> may attempt to establish a connection with the replacement I/O component <NUM> after receiving an indication of the presence of the replacement I/O component <NUM> (e.g., via the backplane <NUM>). For example, the indication may include an identifier of the replacement I/O component <NUM>, an indication of the hardware and/or software compatibility of the replacement I/O component <NUM>, or any other suitable information. The connection request transmitted by the controller <NUM> may include configuration information associated with the replacement I/O component <NUM> to the replacement I/O component <NUM>. For example, the configuration information may include a mode of operation (e.g., suplex mode or duplex mode) associated with the replacement I/O component <NUM> and/or an identifier associated with a partner I/O component (e.g., redundant I/O component <NUM>) for the replacement I/O component <NUM>.

After receiving the connection request from the controller <NUM>, at block <NUM>, the replacement I/O component <NUM> may determine whether the replacement I/O component <NUM> may accept the connection to the controller <NUM> based on the received configuration information. For example, if the configuration information is indicative of the duplex mode of operation and a partner I/O component has been detected (e.g., at block <NUM>), the replacement I/O component <NUM> may accept the connection to the controller <NUM> after verifying with the partner I/O component (e.g., the redundant I/O component <NUM>) that the duplex configuration is correct and matches the configuration of the partner I/O component, determining whether the replacement I/O component <NUM> is the primary component or the secondary component in the potential pair of redundant I/O components, performing a time synchronization with the partner I/O component, or a combination thereof. Alternatively, if the configuration information is indicative of the duplex mode of operation but a partner I/O component was not detected (e.g., at block <NUM>), the replacement I/O component <NUM> may accept the connection to the controller <NUM> after verifying that the duplex mode of operation is the correct configuration for the replacement I/O component <NUM>. For instance, the replacement I/O component <NUM> may transmit a request to the controller <NUM> to confirm the designation of the duplex mode of operation. If the controller <NUM> confirms that the designation of the duplex mode of operation is valid, the replacement I/O component <NUM> may accept the connection to the controller <NUM>. If the controller <NUM> does not confirm that the designation of the duplex mode of operation is valid, the replacement I/O component <NUM> may not accept the connection to the controller <NUM> and may enter a "standby" or a "rest" mode (e. g, at block <NUM>). Alternatively, if (<NUM>) the configuration information is indicative of the duplex configuration and the partner I/O component (e.g., redundant I/O component <NUM>) was determined to have an incompatible hardware and/or software configuration or (<NUM>) the configuration information is indicative of the suplex configuration, the replacement I/O component <NUM> may accept the connection to the controller after verifying the absence of conflicts with neighboring I/O components, verifying that the suplex configuration is valid, or both. However, if one or more of the conditions described above for accepting the connection to the controller <NUM> are not satisfied, the replacement I/O component <NUM> may not accept the connection to the controller <NUM> and may enter a "standby" or a "rest" mode (e. g, at block <NUM>).

After accepting the connection to the controller <NUM>, at block <NUM>, the replacement I/O component <NUM> may proceed to pair with the partner I/O component (e.g., the redundant I/O component <NUM>) if the configuration information associated with the replacement I/O component <NUM> is indicative of the duplex mode of operation. In particular, the replacement I/O component <NUM> and the redundant I/O component <NUM> may negotiate a suitable time for each pair of isolated channels between the replacement I/O component <NUM> and the redundant I/O component <NUM> to switch to the duplex mode of operation. In certain embodiments, the replacement I/O component <NUM> may generate a schedule that defines a particular time or a particular time period for performing the pairing procedure between the replacement I/O component <NUM> and the redundant I/O component <NUM> and transmits the schedule to the redundant I/O component <NUM>. After receiving the schedule from the replacement I/O component <NUM>, the redundant I/O component <NUM> may determine whether the schedule for the pairing procedure does not conflict with its own schedule for performing one or more operations. If the redundant I/O component <NUM> determines that the schedule for the pairing procedure does not conflict with its own schedule for performing one or more operations, the redundant I/O component <NUM> may accept the received schedule for the pairing procedure. For example, the redundant I/O component <NUM> may transmit a signal or a message indicative of the acceptance to the replacement I/O component <NUM>. However, if the redundant I/O component <NUM> determines that the pairing procedure conflicts with its own schedule for performing one or more operations, the redundant I/O component <NUM> may generate a new schedule for completing the pairing procedure and transmit the new schedule to the replacement I/O component <NUM>. After receiving the new schedule from the redundant I/O component <NUM>, the replacement I/O component <NUM> may accept the new schedule. For example, the replacement I/O component <NUM> may transmit a signal or a message indicative of the acceptance to the redundant I/O component <NUM>.

Claim 1:
An input/output, I/O, system (<NUM>) of an industrial automation system (<NUM>), comprising:
a terminal block (<NUM>) comprising a plurality of terminals configured to couple to respective redundant I/O components;
a first redundant I/O component (<NUM>) removably coupled to a set of terminals of the plurality of terminals; and
a second redundant I/O component (<NUM>) removably coupled to the set of terminals of the plurality of terminals, wherein the first redundant I/O component (<NUM>) and the second redundant I/O component (<NUM>) are configured to operate in a duplex mode of operation;
wherein the first redundant I/O component (<NUM>) is configured to perform a first set of operations, comprising:
receiving a signal indicative of an unlocking of the first redundant I/O component (<NUM>) from the terminal block (<NUM>);
generating a schedule for disengaging the first redundant I/O component (<NUM>) from the terminal block (<NUM>);
transmitting the schedule to the second redundant I/O component (<NUM>);
receiving a new schedule from the second redundant I/O component (<NUM>); and
disengaging from the set of terminals based on the new schedule; and
wherein the second redundant I/O component (<NUM>) is configured to perform a second set of operations, comprising:
receiving the schedule from the first redundant I/O component (<NUM>);
determining that the schedule conflicts with one or more operations associated with the second redundant I/O component (<NUM>);
generating the new schedule for disengaging the first redundant I/O component (<NUM>) from the terminal block (<NUM>);
transmitting the new schedule to the first redundant I/O component (<NUM>); and
reconfiguring the second redundant I/O component (<NUM>) to operate in a single duplex, "suplex", mode of operation.