Patent Application
20220272841
The subject matter disclosed herein relates to the field of automation control systems, such as those used in industrial and commercial settings. More particularly, embodiments of the present invention relate to techniques for providing, accessing, configuring, operating, or interfacing with input/output (I/O) devices that are configured for coupling and interaction with an automation controller.
Automation controllers are special purpose computers used for controlling industrial automation and the like. Under the direction of stored programs, a processor of the automation controller examines a series of inputs (e.g., electrical input signals to the automation controller) reflecting the status of a controlled process and changes outputs (e.g., electrical output signals from the automation controller) based on analysis and logic for affecting control of the controlled process. The stored control programs may be continuously executed in a series of execution cycles, executed periodically, or executed based on events. The inputs received by the automation controller from the controlled process and the outputs transmitted by the automation controller to the controlled process are normally passed through one or more I/O devices, which are components of an automation control system that serve as an electrical interface between the automation controller and the controlled process.
Traditional I/O devices typically include a base configured to couple the I/O device with a bus bar, communication bus, or the like, a terminal block for communicatively coupling the I/O device with field devices, and an I/O module that includes circuitry for performing communication functions and/or logic operations. In traditional automation control systems, the I/O module may be coupled to the base by pushing the module toward the base. Friction or a simple locking mechanism between parts of the I/O module and the base may help prevent the I/O module from disengaging from the base. In the past, locking toggle mechanisms have been employed to secure an I/O module to a base. In other arrangements, screws or other fasteners are used to secure an I/O module to a base. The I/O module may be removed from the base by pulling the I/O module away from the base.
It is now recognized that it is desirable to provide more efficient and effective techniques for coupling, locking, and uncoupling I/O modules from bases of I/O devices. In accordance with one aspect of the present disclosure, an I/O system comprises an I/O base having a first connector component, an I/O module selectively attachable to the I/O base and having a second connector component adapted to mate with the first connector component, and a locking actuator assembly for securing the I/O module to the I/O base. The locking actuator assembly includes an actuator supported for axial and rotational movement by the I/O module, the actuator movable from an unlocked position having a first end of the actuator extending from a housing of the I/O module to a locked position wherein a second end of the actuator extends from the housing, the second end of the actuator including at least one flange adapted to pass through a corresponding slot/opening in a surface of the I/O base such that when the actuator is rotated the at least one flange restricts withdrawal of the actuator from the slot/opening in the I/O base.
The second connector component can be supported by a circuit board within the housing, and the actuator can be supported by a bracket secured to the circuit board adjacent the second connector component. The bracket can include a support having first and second ends secured to the circuit board at outboard locations of the circuit board such that a major portion of a width of the circuit board is bridged by the support. The support can include a cylindrical portion between its first and second ends through which the actuator extends. The assembly can further include a cap secured to the support, the cylindrical portion of the support and the cap defining a cavity in which at least one radially extending guide flange of the actuator is received. The cap and the cylindrical portion can define at least one slot in which the at least one guide flange is received, the at least one slot delimiting axial and rotational movement of the actuator. The at least one slot can be L-shape, having a first portion of the L-shape extending axially and a second portion of the L-shape extending circumferentially. A biasing element can be interposed between the at least one guide flange and the cylindrical portion of the support, the biasing element urging the actuator axially towards to unlocked position. The first end of the actuator can extend from a first exterior side of the housing of the I/O device when in the unlocked position, and wherein the second end of the actuator extends from a second exterior side of the housing opposite the first exterior side when in the locked position. The support can be secured to the circuit board adjacent the second exterior side of the housing.
In accordance with another aspect, a locking actuator assembly for selectively securing together associated first and second devices of an associated I/O system comprises a locking actuator assembly including an actuator supported for axial and rotational movement by a circuit board of the associated first device, the actuator movable from an unlocked position to a locked position upon axial depression and rotation of a first end of the actuator, wherein a second end of the actuator includes at least one flange adapted to pass through a corresponding slot/opening in a surface of the associated second device such that when the actuator is rotated the at least one flange restricts withdrawal of the actuator from the slot/opening in the surface of the associated second device.
The circuit board can support a first connector component adapted to mate with a second connector component of the associated second device, and the actuator can be supported by a bracket secured to the circuit board adjacent the connector component. The actuator can be supported by the support at a location between first and second ends of the support, the first and second ends of the support being secured to the circuit board at outboard locations thereof such that a major portion of a width of the circuit board is bridged by the support. A cylindrical portion of the bracket and a cap secured to the bracket define a cavity in which a radially extending guide flange of the actuator is received. The cap and the cylindrical portion define at least one slot in which the at least one radially extending guide flange is received, the at least one slot delimiting axial and rotational movement of the actuator. The at least one slot can be L-shape having a first portion of the L-shape extending axially and a second portion of the L-shape extending circumferentially. A biasing element can be interposed between the at least one guide flange and the cylindrical portion of the support, the biasing element urging the actuator axially towards to unlocked position. The bracket can be secured to the circuit board adjacent an edge thereof, and the actuator can be coextensive with the circuit board in a direction perpendicular to the bracket.
In accordance with another aspect, a method of securing a first device of an I/O system to a second device of an I/O system comprises coupling the first device to the second device, and locking the first device to the second device with a locking actuator assembly. The locking actuator assembly includes an actuator supported for axial and rotational movement by a circuit board of the first device, the actuator movable from an unlocked position to a locked position upon axial depression and rotation of a first end of the actuator, wherein a second end of the actuator includes at least one flange adapted to pass through a corresponding slot in a surface of the second device such that when the actuator is rotated the at least one flange restricts withdrawal of the actuator from the slot/opening in the surface of the second device. Locking the first device to the second device can include depressing and rotating the first end of the actuator from an external side of the first device opposite the second device.
The control and monitoring system is generally indicated by reference numeral 10. Specifically, the control and monitoring system 10 is illustrated as including a human machine interface (HMI) 12 and an automation controller or control/monitoring device 14 adapted to interface with components of a process 16.
The illustrated process 16 includes sensors 18 and actuators 20. The sensors 18 can include any number of devices adapted to provide information regarding process conditions. The actuators 20 can include any number of devices adapted to perform a mechanical action in response to a signal from a controller (e.g., an automation controller). The sensors 18 and actuators 20 can be utilized to operate process equipment. Indeed, they can be utilized within process loops that are monitored and controlled by the control/monitoring device 14 and/or the HMI 12. Such a process loop can be activated based on process inputs (e.g., input from a sensor 18) or direct operator input received through the HMI 12.
As illustrated, the sensors 18 and actuators 20 are in communication with the control/monitoring device 14 and may be assigned a particular address in the control/monitoring device 14 that is accessible by the HMI 12. As illustrated, the sensors 18 and actuators 20 can communicate with the control/monitoring device 14 via one or more I/O devices 22 coupled to the control/monitoring device 14. The I/O devices 22 can transfer input and output signals between the control/monitoring device 14 and the controlled process 16. The I/O devices 22 can be integrated with the control/monitoring device 14, or can be added or removed via expansion slots, bays or other suitable mechanisms. For example, additional I/O devices 22 can be added to add functionality to the control/monitoring device 14.
The I/O devices 22 can include input modules that receive signals from input devices such as photo-sensors and proximity switches, output modules that use output signals to energize relays or to start motors, and bidirectional I/O modules, such as motion control modules which can direct motion devices and receive position or speed feedback. In some arrangements, the I/O devices 22 can convert between AC and DC analog signals used by devices on a controlled machine or process and DC logic signals used by the control/monitoring device 14.
Each of the I/O devices 22 includes a base 28 for physically and communicatively connecting the I/O device 22 to the DIN rail 26, the I/O adapter 24 and/or adjacent I/O devices 22, a terminal block 30, and one or more I/O modules 32. The terminal block 30 may be used to electrically connect the I/O device 22 to field devices, such as the sensors 18 and actuators 20 illustrated in
With reference to
In accordance with the present disclosure, each I/O module 32′ includes a locking actuator assembly 40 for securing the I/O module 32′ to the base 24′. With additional reference to
A first end 60 of the actuator 42 includes a slot 62 for engagement with a tool, such as a screwdriver, for depressing and rotating the actuator 42. It will be appreciated that other arrangements for facilitating depression and rotation of the actuator 42 can be employed without departing from the scope of the present disclosure, such as hex or torx arrangements, knobs etc. An opposite end 66 of the actuator 42 includes radially outwardly extending flanges F giving the actuator 42 a T-shape cross-section. The end 66 of the actuator 42 protrudes beyond the housing 44 when the actuator 42 is in the locked position, as best seen in
Turning to
With additional reference to
As best seen in
Flanges 82 of the actuator 42 are captured between the barrel portion 76 of the bracket 46 and the cap 94, and a biasing element in the form of a coil spring S (see
It should be appreciated that the flanges 82, being received in the L-shape slots 92 of the bracket 46, restrict both reciprocating and rotational movement of the actuator 42. In
It will now be appreciated that the I/O module 32′ can be secured to the base 24′ after engagement of the connector component C2 of the I/O module 32′ with the connector component C1 of the base 24′ by depressing end 60 of the actuator and then rotating the actuator clockwise 90 degrees.
Returning to
It should be appreciated that springs having various spring constants can be employed to apply a wide range of holding forces. In some embodiments, the spring S can be omitted. In many applications, however, the spring-loaded actuator is desirable for accommodating tolerance stack-up in the various components of the I/O system and/or the locking actuator assembly 40.
It should also be appreciated that the locking actuator assembly 40 of the present disclosure locates the interlocking features (e.g., flanges F and opening O) in close proximity to the connector components C1 and C2 of the I/O module 32′ and base 24′. This results in a more compact force path between the interlocked components. For example, the actuator 42 engages the circuit board 38 of the base 24′ in close proximity to the attachment points/fasteners 72 of the support 46 to the main circuit board 52. As such, a major portion of the actuator 42 is not under load in the locked position, the forces instead being transferred from the flanges F to the flanges 82 through spring S to barrel portion 78 and to the main circuit board 52 via the support 46. However, the actuator 42 remains conveniently accessible from an outer surface of the I/O module 32′, and also provides a visual indication of the status (e.g., locked or unlocked) of the locking actuator assembly (e.g., the actuator end 60 is proud of the housing 46 when unlocked, and flush with the housing 46 when locked). Interlocking the circuit boards 38 and 52 in close proximity to the connector pair achieves a more reliable connection between the connector pairs, and eliminates any tolerance stack-up that would result from interlocking, for example, the housings of an I/O module and I/O base.
As shown best in
Turning to
It should be appreciated that the form and function of the locking actuator assemblies 40″ and 40′″ are the same as locking actuator assembly 40 described in detail above except for the structure attaching them to the circuit boards.
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.
