REMOVABLE TERMINAL BLOCK ASSEMBLY THAT PERMITS AN I/O BASE TO OPERATE IN SIMPLEX MODE OR DUPLEX MODE
An I/O device includes an I/O base, at least two I/O modules supported on the I/O base, and a duplex terminal block assembly supported on the I/O base. The at least two I/O modules include a first I/O module and a second I/O module coupled to the duplex terminal block assembly in parallel. The duplex terminal block assembly can include connectors for connecting to a field device. The duplex terminal block assembly can include conductive structures for coupling the connectors with each of the first and second I/O modules. The duplex terminal block can be installed in a pair of ports in an I/O base to connect two I/O modules in parallel.
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The present development relates to industrial automation control systems and, more particularly, to a modular input/output (I/O) system having terminal blocks for coupling I/O modules to other components.
BACKGROUND INFORMATIONDistributed modular input/output (I/O) systems for industrial automation control fcsystems are well-known and in widespread use. Referring to
The adapter 12 includes an adapter base 12a that is mounted to a DIN rail D or other support structure, and an adapter module 12b is permanently or releasably connected to the adapter base 12a. The adapter module 12b includes the electronic circuitry for data communication data with the controller C via network N and for data communication with multiple I/O devices 20 of the system 10 as described below. The adapter 12 comprises one or more network connectors NC for connecting with the network N via known connectors such as RJ45 connectors, Small FormFactor Pluggable (SFP) connectors, or the like. The adapter 12 typically also includes a power input connector PC for connecting with a source of electrical power for supplying electrical power to the adapter module 12 and to the I/O devices 20 and other components operatively connected to the adapter 12 and/or I/O devices 20.
The I/O devices 20 each include an I/O base 20a also mounted to the DIN rail D or other support structure, with a first I/O base 20a located adjacent and operably physically and electrically connected to the adapter base 12a by a multi-contact electrical connector K and with the additional I/O bases 20a operably physically and electrically connected together one after the other in a sequential manner by successive mating multi-contact electrical connectors K such that a modular backplane circuit or “backplane” (illustrated as a broken line 14) is constructed and adapted for communicating electrical power and data through the successively connected I/O bases 20a and operably connects each I/O base 20a to the network adapter 12 and, thus, to the controller C. In addition to the I/O base 20a, each I/O device 20 further comprises an I/O module 20b operatively removably connected to the I/O base 20a such that the installed I/O module 20b also communicates with the network adapter 12 and the controller C over the backplane 14 such that input/output data are provided between the controller C and each I/O module 20b via backplane 14. Each installed I/O module 20b is selected and configured to perform one or more specialized input/output functions such as DC input, DC output, AC input, AC output, analog input and/or output, RTD and/or thermocouple input and/or thermocouple output, or the like as is generally known in the field of industrial automation.
Each I/O base 20a further includes a terminal block 20c comprising a plurality of cage clamps, spring clamps, screw terminals, or other wiring connectors 20d that are adapted to be connected to field cables or field wires FW that are each associated with a field device FD that is typically an analog or digital device such as a sensor, flow meter, switch, probe, thermocouple, RTD, encoder, or the like that is associated with the process or machine being controlled (the controlled system CS) by the controller C. The terminal block 20c can be a separate structure that is assembled to the I/O base 20a or can alternatively be defined as an integral or one-piece part of the I/O base 20a. Different varieties of terminal blocks 20a can be used depending upon the particular configuration required for the field device wiring connectors 20d, with some having different common terminals, ground connections, voltage supply terminals, and the like. Each installed I/O module 20b communicates with the field device wiring connectors 20d of the same I/O base 20a to which the I/O module 20b is physically connected. Input/output data are provided between the controller C and field device(s) FD connected to the corresponding I/O base 20a via backplane 14 and the network adapter module 12b.
The systems of
In accordance with one aspect of the present development, an I/O device includes an I/O base, at least two I/O modules supported on the I/O base, and a duplex terminal block assembly supported on the I/O base. The at least two I/O modules include a first I/O module and a second I/O module coupled to the duplex terminal block assembly in parallel.
The duplex terminal block assembly can include connectors for connecting to a field device. The duplex terminal block assembly can include conductive structures for coupling the connectors with each of the first and second I/O modules.
The duplex terminal block assembly can include a terminal block base and a terminal block supported on the terminal block base. The terminal block base can have a width that is twice the width of the terminal block. The terminal block can be centered along the width of the terminal block base. The terminal block can be received in a slot of the terminal block base. The I/O device can further include a third I/O module and a simplex terminal block assembly electrically coupled to the third I/O module. The simplex terminal block assembly can have a width that is half the width of the duplex terminal block assembly. The I/O base can includes a plurality of ports (sometimes referred to as terminal block landing points), each port adapted to couple one of the plurality of I/O modules to a terminal block assembly, and wherein the duplex terminal block is received in at least two ports associated with the first and second I/O modules, and wherein the simplex terminal block is received in a port associated with the third I/O module.
In accordance with another aspect, a duplex terminal block assembly for use with an associated I/O device having an I/O base with at least two ports for receiving at least a portion of a terminal block assembly and at least two I/O modules supported on the I/O base, the duplex terminal block assembly includes a terminal block base portion having connectors for coupling with the I/O base of the associated I/O device, and a terminal block extending from the terminal block base portion and having connectors for connecting to an associated field device. The terminal block base portion has a width such that it is at least partially received in each of the at least two ports when installed in the I/O base, and the duplex terminal block includes conductive structures for coupling each of the at least two I/O modules in parallel to the connectors.
The terminal block base portion can have a width that is twice the width of the terminal block. The terminal block can be centered along the width of the terminal block base portion. The terminal block and terminal block base portion can be separate components assembled together to form the duplex terminal block assembly. The terminal block can be received in a slot of the terminal block base portion.
In accordance with another aspect, a method of assembling an I/O device having at least two I/O modules connected in duplex to a field device includes coupling at least two I/O modules to an I/O base, and coupling a duplex terminal block to first and second ports of the I/O base. The duplex terminal block assembly includes a terminal block base portion having connectors for coupling with the I/O base of the associated I/O device, and a terminal block extending from the terminal block base portion and having connectors for connecting to the associated field device. The terminal block base portion has a width such that it is at least partially received in each of the at least two ports when installed in the I/O base. The duplex terminal block includes conductive structures for coupling each of the at least two I/O modules in parallel to the connectors.
The distributed modular I/O system 110 includes a network adapter 112 that is operatively connected to both first and second redundant industrial automation networks N1,N2 such as first and second Parallel Redundancy Protocol (PRP) LAN networks or the like such as an Ethernet/IP network or other industrial automation network so that the network adapter 112 receives data from, transmits data to, and otherwise communicates with one or more industrial control modules or “controllers” C1,C2 connected respectively to the networks N1,N2. The controllers C1,C2 can comprise one or more programmable logic controllers (PLC), microprocessors, and/or other electronic processors for machine and/or process control.
The network adapter 112 includes an adapter base 112a that is mounted to a rail D′ or other support structure. The network adapter 112 further comprises first and second redundant adapter modules 112b1,112b2 that are operating in parallel with each other and each of which is permanently or releasably connected to the adapter base 112a. Each adapter module 112b1,112b2 is connected to both the first and second networks N1,N2 and includes the electronic circuitry for data communication data with the controllers C1,C2 via networks N1,N2 and for data communication with multiple I/O devices 120 of the system 110 as described below. The adapter 112 comprises one or more network connectors NC for connecting with the networks N1,N2 via known connectors such as RJ45 connectors, Small FormFactor Pluggable (SFP) connectors, or the like.
The network adapter 112 further comprises first and second redundant power conditioning modules 116a,116b connected to the adapter base 112a and each including a power input connector PC for connecting with a source of electrical power for supplying system electrical power to the network adapter 112 and to the I/O devices 120 and other components operatively connected to the adapter 112 and/or I/O devices 120.
The I/O system 110 further comprises one or more I/O devices 120 that each include an I/O base 120a also mounted to the support rail D′ or other support structure, with a first I/O base 120a located adjacent and operably physically and electrically connected to the adapter base 112a by a multi-contact electrical connector K and with the additional I/O bases 120a operably physically and electrically connected together one after the other in a sequential manner by successive mating multi-contact electrical connectors K such that a modular backplane circuit or “backplane” (schematically illustrated at 114) is constructed and adapted for communicating electrical power and data through the successively connected I/O bases 120a and operably connects each I/O base 120a to the network adapter 112 and, thus, to the first and second networks N1,N2 and the first and second controllers C1,C2.
In addition to the I/O base 120a, each I/O device 120 further comprises at least two I/O modules 120b (120b1, 120b2, 120b3, 120b4, in
In the illustrated embodiment, each I/O device 120 comprises four I/O modules 120b (120b1,120b2,120b3,120b4) operatively removably connected to the I/O base 120a, and at least two of the I/O modules 120b are identical to each other and operated in parallel to provide a redundancy with respect to each other (as shown, the I/O modules 120b3,120b4 of the two illustrated I/O devices 120 are identical and operated redundantly in parallel with respect to each other).
Each I/O base 120a further supports two types of terminal blocks 120c1 and 120c2 comprising a plurality of cage clamps, spring clamps, screw terminals, or other wiring connectors 120d that are adapted to be connected to field cables or field wires FW that are each associated with a field device FD that is typically an analog or digital device such as a sensor, flow meter, switch, probe, thermocouple, RTD, encoder, or the like that is associated with the process or machine being controlled (the controlled system CS) by the controllers C1,C2. In the illustrated embodiment, each terminal block 120c1/120c2 is a separate structure that is assembled to the I/O base 120a, but in some embodiments the terminal blocks can be defined as an integral or one-piece part of the I/O base 120a. Different varieties of terminal blocks can be used depending upon the particular configuration required for the field device wiring connectors 120d, with some having different common terminals, ground connections, voltage supply terminals, and the like. Each installed I/O module 120b communicates with the field device wiring connectors 120d of the same I/O base 120a on which the I/O module 120b is physically installed. Input/output data are provided between the controllers C1,C2 and field device(s) FD connected to the corresponding I/O base 120a via backplane 114 and the network adapter modules 112b1,112b2.
In the illustrated embodiment, the redundant, parallel I/O modules 120b3,120b4 share a common terminal block 120c2 such that the redundant I/O modules 120b3,120b4 are operably connected to the same field wiring FW and field device FD to send data to and receive data from the controlled system. I/O modules 120b1 and 120b2 are coupled to respective terminal blocks 120c1 for communication to respective field wiring FW. It should now be appreciated, that terminal blocks 120c1 and 120c2 differ in form and function from each other, with terminal block 120c1 configured to connect a single I/O module to associated field wiring FW (simplex mode) and terminal block 120c2 configured to couple two I/O modules to associated field wiring FW (duplex mode).
Turning to
In
The terminal block 120c2 is sometimes referred to as a duplex terminal block as it can be used to connect two I/O modules to a common field device in systems where redundancy is required or desired. In contrast, and with reference to
The terminal block assemblies 120c12 and 120c2 allow customization of an I/O system having at least two slots for receiving I/O modules and corresponding ports for receiving terminal block assemblies. Although the illustrated embodiment is directed to a quad slot I/O device, aspects of the present disclosure can be adapted to any I/O device having at least 2 slots. It should be appreciated that the terminal block TB in each of the terminal block assemblies 120c1 and 120c2 is a common element that can be used with either terminal block base TBB1 or TBB2. This construction further enhances the modularity of the I/O system by allowing a single terminal block TB to be used in either duplex or simplex fashion depending on the terminal block base to which it is associated. Although it should be appreciated that separate, dedicated terminal blocks can be provided in accordance with aspects of the present disclosure. Aspects of the present disclosure facilitate customization of I/O devices in the field by allowing a technician to select a terminal block assembly for a particular application depending on whether simplex or duplex functionality is desired, and/or to easily retrofit existing installations for duplex functionality.
Turning to
In
In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.
Claims
1-6. (canceled)
7. An I/O device comprising: wherein the terminal block is received in a slot of the terminal block base.
- an I/O base;
- at least two I/O modules supported on the I/O base; and
- a duplex terminal block assembly supported on the I/O base;
- wherein the at least two I/O modules include a first I/O module and a second I/O module coupled to the duplex terminal block assembly in parallel;
- wherein the duplex terminal block assembly includes a terminal block base and a terminal block supported on the terminal block base, the terminal block base having a width that is twice a width of the terminal block and the terminal block is centered along the width of the terminal block base; and
8. An I/O device comprising: further comprising a third I/O module and a simplex terminal block assembly electrically coupled to the third I/O module.
- an I/O base;
- at least two I/O modules supported on the I/O base; and
- a duplex terminal block assembly supported on the I/O base;
- wherein the at least two I/O modules include a first I/O module and a second I/O module coupled to the duplex terminal block assembly in parallel; and
9. The I/O device of claim 8, wherein the simplex terminal block assembly has a width that is half a width of the duplex terminal block assembly.
10. The I/O device of claim 9, wherein the I/O base includes a plurality of ports, each port adapted to couple one of the plurality of I/O modules to a terminal block assembly, and wherein the duplex terminal block is received in at least two ports associated with the first and second I/O modules, and wherein the simplex terminal block is received in a port associated with the third I/O module.
11. A duplex terminal block assembly for use with an associated I/O device having an I/O base with at least two ports for receiving at least a portion of a terminal block assembly and at least two I/O modules supported on the I/O base, the duplex terminal block assembly comprising:
- a terminal block base portion having connectors for coupling with the I/O base of the associated I/O device; and
- a terminal block extending from the terminal block base portion and having connectors for connecting to an associated field device;
- wherein the terminal block base portion has a width such that it is at least partially received in each of the at least two ports when installed in the I/O base; and
- wherein the duplex terminal block includes conductive structures for coupling each of the at least two I/O modules in parallel to the connectors.
12. The duplex terminal block assembly of claim 11, wherein the terminal block base portion has a width that is twice a width of the terminal block.
13. The duplex terminal block assembly of claim 12, wherein the terminal block is centered along the width of the terminal block base portion.
14. The duplex terminal block assembly of claim 13, wherein the terminal block and terminal block base portion are separate components assembled together to form the duplex terminal block assembly.
15. The duplex terminal block assembly of claim 14, wherein the terminal block is received in a slot of the terminal block base portion.
16. A method of assembling an I/O device having at least two I/O modules connected in duplex to a field device, the method comprising:
- coupling at least two I/O modules to an I/O base;
- coupling a duplex terminal block to first and second ports of the I/O base;
- wherein the duplex terminal block assembly includes a terminal block base portion having connectors for coupling with the I/O base of the associated I/O device, and a terminal block extending from the terminal block base portion and having connectors for connecting to the associated field device;
- wherein the terminal block base portion has a width such that it is at least partially received in each of the at least two ports when installed in the I/O base; and
- wherein the duplex terminal block includes conductive structures for coupling each of the at least two I/O modules in parallel to the connectors.
Type: Application
Filed: Sep 26, 2019
Publication Date: Apr 1, 2021
Applicant: Rockwell Automation Technologies, Inc. (Mayfield Heights, OH)
Inventors: Adam M. Wrobel (Gates Mills, OH), Doug A. Lostoski (Richfield, OH), Daniel E. Killian (Eastlake, OH)
Application Number: 16/583,971