This disclosure relates generally to physical connections between an input/output (I/O) module and a terminal base in automation systems.
In general, I/O interfaces used in automation systems provide a method for transferring information between sensors, actuators, and automation components that include processors, external devices, internal memory, and external memory. Generally, the I/O module may perform various modifications of signals, while a terminal base supplies connections to peripheral devices, such as sensors and actuators, or processors. Peripheral devices may be electromechanical, electromagnetic, or simple electronic devices. I/O modules may act as a hub or receiving and distribution point for many different devices that provide signals used in automation processes, and signals that command operation of automation components in performing parts of such processes.
Furthermore, such modular I/O may be programmed to exchange signals or data derived from the signals with other automation components in specific ways. The use of a configured I/O module in a system leads to the requirement that only the correct I/O module be coupled to and implemented with the terminal base where it is to be used and the specific components connected via terminals in the base.
Keying systems on I/O interfaces allow only the I/O module with a proper key to fit into a terminal base that has been configured with a keying base to physically receive only that key. The I/O module with the proper key may be placed into the terminal base with no restriction, but an I/O module with a different key may be physically rejected from the base. The removal and engagement of I/O modules may be required due to replacement or upgrade. Additionally, if an upgrade is desired, it may be necessary to change the keying base to prevent the previous module from being placed in the terminal base. Unfortunately, keying bases are generally time consuming to configure and may be permanent once set.
In one embodiment, a keying system for an automation device may include an input/output (I/O) terminal base and an I/O module mountable on the terminal base. In operation, the I/O module exchanges I/O signals with external devices via the terminal base. The I/O module includes a key, and the terminal base includes a locking assembly. The locking assembly includes a housing having parallel slots and a plurality of lock pins movable in the slots between a first, biased position and a second position and each lock pin having a locking structure. The locking assembly also includes, a blocking member that, in operation, is actuated to interface with the locking structures to block each of the lock pins in the respective first or second position and a maintaining member that, in operation, contacts the blocking member to maintain the blocking member in a blocking position in which each of the lock pins is blocked in the respective first or second position. Each lock pins can be displaced between the respective first and second positions by the key that has engaging surfaces that contact the lock pins to define keyed positions of the lock pins. The blocking member blocks the lock pins in their keyed positions and the maintaining member maintains the blocking member in the blocking position thereby blocking mounting of other I/O modules not having the key.
In another embodiment, a keying system for an automation device may include a base configured to perform an automation operation and a modular automation device mountable on the base and that, in operation, exchanges signals with the base. The modular automation device may include a key. The keying system may also include a locking assembly on the base. The locking assembly may include a housing having parallel slots, a plurality of lock pins movable in the slots between a first, biased position and a second position and each having a locking structure, a blocking member that, in operation, is actuated to interface with the locking structures to block each of the lock pins in the respective first or second position, and a maintaining member that, in operation, contacts the blocking member to maintain the blocking member in a blocking position in which each of the lock pins is blocked in the respective first or second position. Each of the lock pins can be displaced between the respective first and second positions by a key having engaging surfaces that contact the lock pins to define keyed positions of the lock pins. The blocking member blocks the lock pins in their keyed positions and the maintaining member maintains the blocking member in the blocking position thereby blocking mounting of other modular automation devices not having the key.
In another embodiment, a keying method for an automation device may include, in a system that comprises an input/output (I/O) terminal base and an I/O module with a key mountable on the terminal base and that, in operation, exchanges I/O signals with external devices via the terminal base, biasing a plurality of lock pins each movable between a first, biased position and a second position. The method may further include actuating a blocking member to interface with locking structures of the lock pins to block each of the lock pins in the respective first or second position, and contacting the blocking member with a maintaining member to maintain the blocking member in a blocking position in which each of the lock pins is blocked in the respective first or second position. Each of the lock pins can be displaced between the respective first and second positions by a key having engaging surfaces that contacts the lock pins to define keyed positions of the lock pins, and wherein the blocking member blocks the lock pins in their keyed positions, and the maintaining member maintains the blocking member in the blocking position thereby blocking mounting of other I/O modules not having the key.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
The disclosure relates generally to physical connections between an input/output (I/O) module and a terminal base. In automation systems, I/O modules are used for receiving and providing signals and data between automation components, such as sensors, actuators, processing components, monitoring and control components, and so forth, and may be implemented by a physical connection to a terminal base connected to one or more such devices. These devices may be in use in large systems such as industrial automation, as well as in smaller systems, OEM equipment, and so forth.
A further employment of an I/O module may be to manage multiple devices at once. Such management may include simply receiving signals and data from sensors during operation of an automated process, outputting signals and data to actuators, exchanging signals and data with monitoring and/or control devices, and so forth. One embodiment of multi-device management may also include multiple I/O modules attached to multiple terminal bases. The bases may also be interconnected to supply further connections. In addition to providing and exchanging signals and data, the I/O modules may provide power for operation of peripherals, particularly sensors and actuators.
Keying systems on I/O interfaces allow only the I/O module with a proper key to fit into a terminal base that has been configured with a keying base to physically receive only that key. The I/O module with the proper key may be placed into the terminal base with no restriction, but an I/O module with a different key may be physically rejected from the base. The removal and engagement of I/O modules may be required due to replacement or upgrade. Additionally, if an upgrade is desired, it may be necessary to change the keying base to prevent the previous module from being placed in the terminal base. Unfortunately, keying bases are generally time consuming to configure and may be permanent once set. The embodiment of the present disclosure illustrates an I/O device that utilizes a keying system that can be automatically keyed with the first insertion of a key, and may be reset to an unkeyed configuration without the use of any tools.
With the foregoing in mind,
To facilitate communication between the machine or process 12, the automation controller 14, sensors 20, and/or other machines or processes, an I/O device 22 is employed that allows for receiving, providing, exchanging, and where desired at least partially processing or conditioning signals and data. A terminal base 24 facilitates wired and/or wireless connections from the automation controller 14, sensors, 20, and/or a machine or process 12 to an I/O module 26 via a physical connection 28. The I/O module 26 may transmit signals and data, and where desired may compute, process, and/or communicate signals and data to and from the connected devices. I/O devices 26 are modular in that they can be removed from the terminal base 24 and be replaced, configured, or upgraded with relative ease. The physical connection 28 made between the I/O module 26 and the terminal base 24 facilitates signal transmission of signals to and from the I/O module, and may be common among many I/O modules configured for different implementations.
To ensure matching and proper operation of the correctly configured I/O module with the desired terminal base, only a specific I/O module 26 should be connected to a matching terminal base 24. To ensure such matching, a keying system comprising a key 30 and a keying base 32 are employed on the I/O module and terminal base 24 respectively. It also may occur to those skilled in the art to place the keying base 32 on the I/O module 26, and the key 30, on the terminal base 32. If the I/O module 26 has the key 30 for which the keying base 32 is set, the physical connection 28 between the I/O module and the terminal base 24 can then be made, allowing for appropriate signals and data exchange via the I/O module with a system network 34.
The network 34 maintains connections between the plurality of devices of the system 10, including one or more automation controllers 14. The automation controllers 14 will typically include one or more processors 36, which may be any suitable types, such as field programmable gate arrays, multi-core processors, or any other suitable processing circuits. The processors 36 are coupled to memory circuitry 38 that stores a range of configuration routines, operating routines, settings, and so forth. The memory circuitry 38 may be of any suitable type, including volatile and non-volatile memory. The processors 36 are also connected to interface circuitry 40 to allow communications with other devices such as a human interface module (HIM) or other auxiliary circuitry.
Further, the system 10 may be in physical, data and/or logical communication with other systems and components via the network 34, both wired and wireless, at a single location or at dispersed locations in an organization. Additionally, the network 34 may employ remote control/monitoring components 42 to facilitate further management of the system 10.
The I/O module 26 may include one or more self-contained processors 44 and memory units 46. These processors 44 may be any suitable types, such as field programmable gate arrays, multi-core processors, or any other suitable processing circuits. Here again, the memory circuitry 38 may be of any suitable type, including volatile and non-volatile memory.
To make the physical connection 28 between I/O module 26 and the terminal base 24, the I/O module is pressed into the terminal base as shown by reference arrow 48. The depiction of the connection 28 being made by arrow 48 is for illustration of one possible embodiment, and is not limiting. Additionally, connections between terminal bases 24 may be made for expansion of the network 34 and system 10. These connections may include a mechanical interlock 50 and/or an electrical interface 52. Reference arrow 54 depicts the joining of two terminal bases 24.
As one skilled in the art would appreciate, the use of I/O devices 22, and therefore keys 30 and keying bases 32, is not limited to industrial automation systems, and the scope of this disclosure is not limited as such.
Additionally, the I/O module 26 may include alignment fins 58 for facilitating proper alignment of the electrical interface 28 and keying system when mounted to the terminal base 24 as shown by reference arrow 48. As might be apparent to anyone skilled in the art, depending on the configuration of the I/O module 26 and terminal base 24, the attachment (see arrow 48) may be via a linear movement (e.g., vertical or horizontal) or rotary movement. If the keying base 32 is keyed for the key 30 of the I/O module 26, a complete connection can be made and a retaining mechanism 60 may be utilized to prevent inadvertent removal of the I/O module. This retaining mechanism may be a clasp, clip, snap, toggle, screw, or other form of non-permanent attachment.
The keying system may be comprised of three main bodies as depicted in
Additionally, an open slot 74 is provided on the face of the top cover assembly 62 to allow components from the bottom cover assembly 64 to be actuated. The bottom cover assembly 64 displayed in
The maintaining levers 76 pivot to actuate one or more blocking bars 78 which, depending on configuration state, may block lock pins 68 from moving. These blocking bars pivot in grooves cut out of the bottom cover assembly 64, top cover assembly 62, or both. The present embodiment employs two maintaining levers 76 and two blocking bars 78 of which one of each is removed in
The two configurations of the keying base 32, unkeyed and keyed, lead to two possible processes for inserting an I/O module 26 into a terminal base 24 as depicted by flow diagrams in
With the keying base 32 in the keyed configuration, an I/O module 26 may be inserted into the terminal base 24 following the keyed process 90. As with the unkeyed process 88, the keyed process 90 begins with an alignment stage 92 for allowing proper connections to be made between the I/O module 26 and the terminal base 24. An acceptance/rejection stage 100 begins when the key 30 comes in contact with the keying base 32. Since the keying base 32 has already been keyed, a compatible key 30 will be accepted into the keying base allowing further insertion of the I/O module 26 into the terminal base 24. However, if the key 30 is not compatible with the keyed keying base 32, the keying fins 84 will be rejected by the lock pins 68 stopping further insertion of the I/O module 26 into the terminal base 24. If the key 30 is accepted, a contact stage 96 will follow, and the electrical connection 28 will be made between the I/O module 26 and the terminal base 24. It should be noted, that the acceptance/rejection stage 100 occurs before any electrical connection 28 can be made.
The keying process described above is depicted by
When the blocking bar 78 is actuated by the maintaining levers 76, the blocking bar travels to a position in front of or behind the pin backs 70 of the lock pins 68. The pin backs 70 protrude from the lock pins 68 in so that the lock pins may be held in a keyed position when the key 30 is removed. As depicted in
It should be noted that some keys 30 with fewer or no keying fins 84 may be compatible with multiple keyed lock pin configurations. For example, a “master key” may have no keying fins 84 and would be accepted in any keyed keying base 32. The “master key,” having no keying fins 84, would not be rejected by a lock pin 68B that is in the default biased position, as there would be no keying fin to make contact with the lock pin. Such a key 30 may be utilized in any employment where the electrical connection 28 to be made desired with terminal bases 24 of multiple keyed configurations such as a diagnostic tool, programming tool, or an I/O module 26 universal to the network 34. It may be noted that lock pin configurations, slot configurations, and key configurations may be altered to increase or decrease prolificacy of compatible keys to a single keyed configuration to reduce user error or confusion.
Moreover, the a reset of the keying base 32 may be achieved quickly and without the use of tools by introducing a small force on the maintaining levers 76 to overcome the detent 82.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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