Patent Description:
<FIG> shows a first example of an industrial control system CS including an industrial automation controller <NUM> and a distributed industrial automation input/output (I/O) system <NUM> operatively connected to the industrial controller. The I/O system <NUM> includes a network adapter module <NUM> providing a connection <NUM> to an industrial data network <NUM>. The data network <NUM> may be any one of a number of industrial control or I/O networks including but not limited to ControlNet, DeviceNet, EtherNet/IP, RIO, ASi, PROFIBUS, PROFInet, Foundation Fieldbus or the like as are well known in the art of industrial automation data networks. The adapter module <NUM> communicates over the network <NUM> with the industrial controller <NUM> to receive output data from the industrial controller or to provide input data to the industrial controller <NUM> to be processed according to a control program executed by a PLC and/or other processor(s) of the industrial controller <NUM>. The network <NUM> can be hard-wired or wireless.

With respect to the I/O system, itself, the adapter module <NUM> communicates with a backplane circuit B (often referred to simply as the "backplane") to operably connect the industrial controller <NUM> to one or more I/O modules <NUM> that are operably connected to the backplane B. In the illustrated embodiment, a physical base or chassis <NUM> is provided to contain the adapter module <NUM> and to contain the I/O modules <NUM>. At least the I/O modules <NUM>, and optionally also the adapter module <NUM>, are selectively insertable and removable to/from the chassis <NUM> to provide the modularity required for customization, module repair/replacement, expansion capability, and the like.

The I/O modules <NUM> connect via I/O field lines <NUM> (e.g., electrical cables, fiber optic cables, etc.) with a controlled device or process 26a,26b,26c,etc. (generally <NUM>) which can be a machine, a sensor, or another device or process, or several or portions of same. As is understood in the art, the I/O modules <NUM> convert digital data received over the backplane B from the controller <NUM> and adapter module <NUM> into output signals (either digital or analog) in a form suitable for input to an industrial process <NUM>. The I/O modules <NUM> typically also receive digital or analog signals from an industrial process <NUM> and convert same to digital data suitable for transmission on the backplane B to the adapter module <NUM> and, thereafter, to the controller <NUM> for processing.

<FIG> is similar to <FIG> but shows an alternative industrial automation control system CS' in which the industrial controller <NUM> is also mechanically connected to the chassis <NUM> and directly operably connected to the backplane B for communication of data to and from the I/O modules <NUM>, in which case the adapter module <NUM> is eliminated. In such case, the industrial controller <NUM> and the I/O modules <NUM> communicate with each other directly over the backplane circuit B.

In either the example of <FIG>, modularity of the I/O modules <NUM> with respect to the chassis <NUM> and backplane B is provided through an electrical module connector <NUM> on each I/O module <NUM> which may be mated with any one of a number of corresponding electrical backplane connectors <NUM> extending from and operatively connected to the backplane B. The backplane connectors <NUM> are each associated with a respective physical and logical module mounting location or "slot," and the chassis <NUM> provides mechanical features (not shown) associated with each slot for mechanically releasably securing each I/O module <NUM> to the chassis <NUM> in its operative position.

Furthermore, for both of the above-described systems CS,CS' of <FIG>, each I/O module <NUM>, itself, includes multiple I/O communications channels 22a,22b,22c,etc. (generally <NUM>), such that each I/O module <NUM> can be operably connected to communicate with a corresponding multiple number of field devices or processes <NUM>. One deficiency of known systems is that the I/O channels <NUM> of each module <NUM> are manufactured with a select type (analog or digital, input or output) that cannot be altered after the module <NUM> is manufactured and that cannot be customized for a particular user's requirements. This limitation often requires that an end-user purchase more modules <NUM> than desired in order to have the required types of I/O channels for a particular application, even though certain I/O channels (of the type not needed for that particular application) are not being used. Another drawback associated with known systems is that a failure of one of the I/O channels 22a,22b,22c in a particular I/O module <NUM> requires that the entire I/O module <NUM> be removed and replaced, even though only one of the channels <NUM> of the module has failed. This is highly undesirable because replacement of an I/O module <NUM> for failure of a single channel <NUM> of the module creates a significant expense for replacement of the complete I/O module. Also, every device or process <NUM> connected to not only the faulty I/O channel <NUM> but also the properly functioning I/O channels <NUM> of the module <NUM> must be stopped and disconnected from the I/O module <NUM> until a replacement module <NUM> is installed, which typically also requires associated devices and processes <NUM> being controlled to be stopped until the I/O module <NUM> with the defective I/O channel <NUM> is replaced. <CIT> discloses an input-output nest, which has inside it two chambers which each accommodate two input-output printed circuit boards. The input-output printed circuit boards have circuits which perform conversion between the signal forms used on the control device side and the signal forms used on the field devices side. An interface section has the field device side signal wires connected to it and sends and receives these signals to and from an input-output printed circuit board
It is the object of the present invention to provide a more flexible and cost-effective I/O module.

In accordance with one aspect of the present invention, an industrial automation input/output (I/O) module as described in claim <NUM> is provided.

In another aspect of the present invention an industrial automation control system in accordance with claim <NUM> is provided.

<FIG> is a front elevation view of an I/O module <NUM> provided in accordance with the present development and comprising a modular sub-chassis for insertion and removal of individual single I/O channel subsystems or channels C1 - C8. <FIG> is a section view of the I/O module of <FIG> as taken at line <NUM> - <NUM> of <FIG>. The I/O module <NUM> is adapted to be physically connected to the base or chassis <NUM> of <FIG>. The I/O module <NUM> comprises an electrical module backplane connector <NUM> adapted to be operably connected to the electrical backplane connector <NUM> of the chassis <NUM> to operably connect the module <NUM> to the backplane B for communication of power and data between the module <NUM> and backplane <NUM>.

In <FIG>, it can be seen that the module <NUM> comprises a housing or body <NUM> including a front wall 52a, a rear wall 52b, left and right side walls 52c,52d, a top wall 52e, and a bottom wall 52f. In the illustrated example, the front and rear walls 52a,52b are parallel and spaced-apart from each other, the left and right side walls 52c,52d are parallel and spaced-apart from each other and extend between the front and rear walls, and the top and bottom walls 52e,52f are parallel and spaced-part from each other and extend between the left and right side walls 52c,52d. The body <NUM> thus defines an internal space P for containing a primary backplane interface circuit board <NUM> (also sometimes referred to as the "primary board" or "motherboard") and a plurality of single channel I/O circuit boards or other subsystems 55a - <NUM> (generally <NUM> and each sometimes referred to as an "I/O board" or a "daughterboard") respectively associated with and providing the data input/output functionality for the I/O channels C1 - C8. The front wall 52a includes or defines a plurality of slots S1-S8 that are adapted to releasably receive and retain the respective I/O channels C1 - C8 are further described below. The slots S1 - S8 can be physically separate from each other or defined as respective portions of a single open slot.

The primary board <NUM> is operably connected to the module connector <NUM> so that the components of the primary board <NUM> can be selectively operably coupled to the backplane B through a backplane connector <NUM> (<FIG>) with which the module connector <NUM> is mated. As described in more detail below with reference to <FIG>, each of the I/O boards <NUM> is selectively releasably installed in a respective slot S1 - S8 and operably physically and electrically coupled to the primary board <NUM> for communication of power and single channel I/O data between the primary board <NUM> and the installed I/O board <NUM>. The primary board <NUM> includes all electronic devices and circuitry 54e required for communication of power and data to/from the backplane B through the module connector <NUM>, and the electronic circuitry of the primary board <NUM> is thus shared by all of the single channel I/O boards <NUM> connected to the primary board <NUM>. Each single channel I/O circuit board <NUM>, on the other hand, includes electronic devices and circuitry 55e dedicated to a particular I/O function and a particular type of I/O data, e.g., AC digital input, AC digital output, DC digital input, DC digital output, analog input, analog RTD or thermocouple, analog output, Highway Addressable Remote Transducer (HART) input or output modules, or any other specific type of dedicated I/O circuitry associated only with one of the I/O channels C1 - C8. In particular, each I/O circuit board <NUM> comprises electronic circuitry such as AID converters, D/A converters, multiplexers, buffers, counters, controllers, serializers, timers, I/O logic, memory, and/or like electronic devices such that the I/O circuit 55e: (i) connects via field connections <NUM> with the controlled system(s) <NUM>; (ii) converts digital data received from the industrial controller <NUM> via network adapter <NUM> into analog or digital output signals for input to the controlled devices <NUM> or other parts of the controlled system; and/or, (iii) receives digital or analog signals from the controlled field devices <NUM> or elsewhere and converts the received signals to digital data suitable for transmission to the industrial controller <NUM> via network adapter <NUM>.

The I/O circuit board <NUM> of each I/O channel C1 - C8 further comprises an interface connector DC including electrical interface contacts IC. Each I/O channel C1 - C8 further comprises a respective wiring connector WX1 - WX8 (generally WX) that is releasably connected to the interface connector IX of the respective I/O circuit board 55a - <NUM>. Each wiring connector WX includes one or more wire terminals T for operative connection of the I/O field lines <NUM> that are connected to the field devices or processes <NUM>. As shown herein, each wiring connector WX comprises four wire terminals T, but more or fewer wire terminals T can be provided.

Each wiring connector WX is selectively connectable and removable from the respective single channel I/O circuit board <NUM>. More particularly, each wiring connector WX comprises wiring connector contacts WC (<FIG> & <FIG>) that selectively mate with the interface contacts IC of an I/O board interface connector IX. The wiring connector WX mechanically engages with a respective one of the I/O board interface connectors IX such that the connector contacts WC operably mate with the interface contacts IC to allow power and I/O data to flow between the single channel I/O circuit board <NUM> and one or more of the of the field devices/processes <NUM> via wire terminals T and field lines <NUM> using the single I/O channel C1 - C8 provided by the I/O circuit board <NUM>.

<FIG> is similar to <FIG> but shows a different configuration in which certain components have been removed or separated. Each of the wiring connectors WX is selectively releasably connected to said body <NUM> in alignment and association with one of the plurality of slots S1-S8. In <FIG>, it can be seen that the wiring connectors WX6 - WX8 are selectively connectable to the body in respective association and alignment with I/O channel slots S6 - S8 even if the slot is otherwise empty, i.e., even if the I/O channel slots do not include an installed I/O circuit board <NUM> as is the case in <FIG> for slots S6 - S8. In particular, whether or not an I/O circuit board <NUM> is installed in a slot S1 - S8, a wiring connector WX is received and retained in its respective slot S1 - S8 and engages the body <NUM> with a snap-fit or other releasable engagement. If an I/O circuit board <NUM> is fully installed in a slot S1 - S8, as is the case for slots S1,S2, S4,S5 of <FIG>, the wiring connector WX will mate with and engage the interface connector IX of the respective I/O circuit board <NUM> when the wiring connector WX is installed in its slot S1 - S8 such that the respective contacts WC,IC operably mate. Each individual wiring connector WX can also be selectively removed from its slot S1 - S8 with or without removing the corresponding associated I/O circuit board <NUM> from the same slot S1 - S8 and this can facilitate making wiring connections with the wiring connector WX even before the I/O module <NUM> is present or installed, i.e., the field lines <NUM> can be connected to a wiring connector WX in advance of the I/O module <NUM> being present or installed.

Those of ordinary skill in the art will recognize that the above-described features provide an I/O module that is much easier to install, configure, reconfigure, and repair relative to known I/O modules such as the I/O modules <NUM> described in <FIG>. In particular, the ability to physically and electrically separate the wiring connector WX from a respective one of the I/O circuit boards <NUM> allows the field lines <NUM> to be configured and connected between the field device/process <NUM> and to the wiring connector WX in advance, before the I/O module <NUM> and/or before the single channel I/O circuit board <NUM> is selected and/or installed or available, which greatly simplifies the installation process. Once the I/O module is installed and the appropriate single channel I/O circuit board <NUM> is installed in its intended slot S1-S8, the wiring connector WX including the field lines <NUM> already connected to the terminals T thereof is then operatively installed in the corresponding slot S1-S8 so that the wiring connector contacts WC mechanically and electrically mate with the board interface contacts IC. Of course, any individual I/O circuit board <NUM> can be repaired, replaced and/or reconfigured by a reverse process in which the wiring connector WX is separated from its slot S1-S8 so that the wiring connector contacts WC disconnect from the board interface contacts IC without the need for separating the field lines <NUM> from the wiring connector terminals T. The I/O circuit board <NUM> can then be removed from its slot S1-S8 (see arrow R1) and replaced with the same, repaired circuit board or another I/O circuit board <NUM> having the same or a different configuration, all without powering-down the I/O module. In any such repair or reconfiguration process, the field lines <NUM>, wiring connectors WX and I/O circuit boards <NUM> associated with and connected to all other I/O channels C1-C8 of the module <NUM> are unaffected and need not be disconnected.

<FIG> is a partial side view of the I/O module of <FIG> showing a first embodiment of an I/O channel modular sub-chassis SC1 for insertion and removal of the individual I/O channel circuit subsystems or boards <NUM>. In the example of <FIG>, at least part of the primary circuit board <NUM> is located adjacent the module rear wall 52b and electrically connected to the module connector <NUM>. The primary circuit board <NUM> comprises a plurality of I/O board connectors Z respectively associated with the I/O channels C1-C8 and in respective alignment with the slots S1-S8. In addition to the I/O board connectors Z, the modular sub-chassis further comprises ribs R defined in the left and right body side walls 52c,52d, and parallel pairs of the ribs R partially define the slots S1-S8 there between in alignment with the respective I/O board connectors Z (to simplify the drawing, only one pair of ribs R partially defining the slot S1 is shown in <FIG>, but each slot S1 - S8 includes similar ribs R defined in both the left and right body side walls 52c,52d ). As such, the modular sub-chassis SC1 comprises the primary circuit board <NUM> including the I/O board connectors Z, and further comprises the corresponding slots S1-S8 defined at least partially by the ribs R. When an I/O circuit board <NUM> is fully inserted into its slot S1-S8, the corresponding I/O board connector Z mechanically received and retains the I/O circuit board <NUM>, and power and data contacts 55X of the circuit board <NUM> electrically mate with corresponding contacts in the board connector Z for communication of power and data between the I/O board <NUM> and the primary board <NUM> and connector <NUM>.

<FIG> is a partial side view of the I/O module of <FIG> showing a second embodiment of an I/O channel modular sub-chassis SC2 for insertion and removal of individual I/O channel circuit subsystems/boards <NUM>. In the example of <FIG>, at least part of the primary circuit board <NUM> is located adjacent the module right side wall 52d (and/or alternatively the left side wall 52c) - and is electrically connected to the module connector <NUM>. The primary circuit board <NUM> comprises a plurality of I/O board connectors Z respectively associated with the I/O channels C1-C8 and in respective alignment with the slots S1-S8. In addition to the I/O board connectors Z, the modular sub-chassis SC2 further comprises ribs R defined in the side wall 52c opposite the I/O board connectors Z, and parallel pairs of the ribs R partially define the slots S1-S8 there between. As such, the modular sub-chassis SC2 comprises the primary circuit board <NUM> including the I/O board connectors Z, and further comprises the corresponding slots S1-S8 defined at least partially by the ribs R. When an I/O circuit board <NUM> is inserted into its slot S1-S8, the corresponding I/O board connector Z mechanically received and retains one of the lateral edges of the I/O circuit board <NUM>, and power and data contacts 55X of the circuit board <NUM> electrically mate with corresponding contacts in the board connector Z for communication of power and data between the I/O board <NUM> and the primary board <NUM> and connector <NUM>.

Claim 1:
An industrial automation input/output, I/O, module comprising:
a body (<NUM>) defining an internal space (P) including a plurality of slots (S);
a module backplane connector (<NUM>) connected to said body;
a primary backplane interface circuit board (<NUM>) located in said space of said body, said primary backplane interface circuit board electrically connected to said module backplane connector and comprising electronic devices configured to transmit data and power to and from the backplane circuit (B) through said module backplane connector;
a plurality of individual I/O circuit boards (<NUM>) installed respectively in said plurality of slots of said body, each of said I/O circuit boards comprising electronic devices configured to provide a single-channel I/O circuit for input or output of data with respect to an associated field device, wherein:
each of said I/O circuit boards is electrically connected to said primary backplane interface circuit board when installed in a respective one of said slots, and
each of said plurality of I/O circuit boards is selectively removable from its respective slot and from said internal space of said body for selective electrical disconnection of said I/O circuit board from said primary backplane interface circuit board; and
a plurality of wiring connectors (WX) respectively removably engaged with the plurality of I/O circuit boards, each of said wiring connectors comprising at least one wiring terminal (T) adapted to be electrically connected to a field line of an associated I/O field device,
wherein each of said wiring connectors is received and retained in a respective slot by means of a releasable engagement with the body whether or not an I/O circuit board is installed in the slot,
wherein each of said I/O circuit boards comprises an interface connector (IX) comprising interface contacts (IC) and each of said wiring connectors comprises wiring connector contacts (WC), and wherein if an I/O circuit board is fully installed in a slot, a wiring connector will engage an interface connector of the respective I/O circuit board when the wiring connector is installed in the respective slot, such that the respective interface contact and the respective wiring connector contact operably mate, and
wherein each of said wiring connectors is selectably removable from a respective slot with or without removing a corresponding associated I/O circuit board from the same slot.