BACKGROUND

[0001] The present inventions relate generally to controllers, and more

particularly, to alternative selectors for changing interconnections with field devices.

[0002] Control systems interact with a variety of field devices, such as sensors and actuators, to monitor and control numerous types of industrial processes. In some cases where the industrial process is complex, a control system can be required to interact with a large number of field devices. Different types of field devices can also have different interconnection requirements. For example, some field devices may be self-powered or may obtain power in the field from a battery or other power system. On the other hand, other field devices may require power to be supplied from the control system that is connected to the field device. It is also possible for field devices to have different interconnection requirements with the control system for transferring data therebetween. Thus, it can be difficult to design a control system that includes numerous field devices, each of which may have different connection requirements.

[0003] One way that this problem has been dealt with is to design different types of communications modules that are compatible with particular types of field devices. In this arrangement, field devices having similar interconnection requirements can be grouped together on special communication modules that are compatible with the group of field devices. However, this requires numerous different types of communications modules to be provided in order to interconnect all of the various types of field devices that may be used in a particular control system. This raises expenses and complexity in setting up the system.

[0004] Therefore, it would be preferable to provide a universal communications module that can be easily configured to connect various types of field devices with different interconnection requirements.

SUMMARY

[0005] A universal communications module is described for communicating with field devices. The communications module has separate data paths for each field device that may be easily configured according to the particular requirements of the field device. Thus, field devices of different types having different power and/or communications requirements can be supported by a single universal

communications module. Each data channel has a set of pins connected to the field device, the power supply and the signal processing module. Pin selectors with different arrangements of connectors are provided to interconnect the pins according to the requirements of particular types of field devices.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0006] The invention may be more fully understood by reading the following description in conjunction with the drawings, in which:

[0007] Figure 1 is a perspective view of a universal communications module with pin selectors, pin selector keys and signal processing module removed from the base;

[0008] Figure 2 is a perspective view of the universal communications module with pin selectors, pin selector keys and signal processing module connected to the base;

[0009] Figure 3 is a perspective view of the back side of the base;

[0010] Figure 4 is a top view of the universal communications module showing connections to field devices;

[0011] Figure 5 is a schematic view of a single data channel;

[0012] Figure 6 is a perspective view of the universal communications module showing pin selectors and a pin selector key disconnected from the base;

[0013] Figure 7 is an exploded view of a pin selector;

[0014] Figure 8 is a side perspective view of a pin selector and a pin selector key;

[0015] Figure 9 is a bottom perspective view of a pin selector and a pin selector key;

[0016] Figure 10 is a perspective view of pin selectors and a generic tray;

[0017] Figure 1 1 is a schematic view of different pin selectors showing different connection arrangements; and

[0018] Figures 12A-12C are schematic views showing different connection arrangements between field device connectors, a power supply and signal processors. DETAILED DESCRIPTION

[0019] Referring now to the figures, and particularly Figures 1-3, a universal communications module 10 is shown. In Figure 1 , the module 10 is shown with the pin selectors 52, pin selector keys 72, and signal processing module 36 removed. In Figure 2, the pin selectors 52, pin selector keys 72, and signal processing module 36 are connected to the module 10. As shown in Figure 1 , the module 10 has a base 12 with a plurality of pin sets 14 that the pin selector keys 72 and pin selectors 52 are connected to. The base 12 also includes a module connector 16 for connecting the signal processing module 36 to the base 12. The base 12 also includes a series of field device connectors 18 and fuses 20 corresponding to each pin set 14. A power supply connector 22 is also provided on the base 12. As shown in Figure 3, the back side of the base 12 may be provided with a DIN rail connector 24 to mount the universal communications module 10 on a DIN rail 26 in an industrial facility.

The DIN rail connector 24 includes a slot 28 for a DIN rail 26 (Figure 2), fixed hooks 30 for engaging the DIN rail 26, and spring-loaded, slidable hooks 32 for engaging and disengaging the DIN rail 26.

[0020] The base 12 is also provided with a data port 34. The data port 34 preferably transmits addressable data to and from the signal processing module 36, which communicates data to and from sensors 38 and actuators 38 (i.e., field devices 38) connected to the field connectors 18. As shown in Figure 4, it may be particularly preferable for the base 12 to have a data port 34 on each end of the base 12 (with one being a male connection and the other being a female connection). In this arrangement, the data ports 34 may be serial ports 34 and multiple

communications modules 10 may be connected together with the data ports 34. The data ports 34 may thus form a data bus in communication with a central process controller. Although it is possible for the signal processing module 36 plugged into the base 12 to perform process control functions (in other words, process the signals received from the field devices 38), it is most preferred for the signal processing module 36 to be limited to I/O functions. That is, the signal processing module 36 conditions and/or converts the signals received from and transmitted to the field devices 38 to allow a central process controller to communicate with each field device 38. Even more preferred, as shown in Figure 12A, the signal processing module 36 may include a plurality of separate signal processors 40 with limited or no communication therebetween. Thus, each signal processor 40 is assigned to a corresponding field connector 18 to process signals between the respective field device 38 and a central process controller. After passing through a respective signal processor 40, the processed signals are transmitted to and from a central process controller through the data ports 34. Thus, in the preferred embodiment, the signal processors 40 do not apply control logic between different field devices 38 (i.e. , separate data channels 42), but instead, allow communication between the field devices 38 and a central process controller which applies control logic between different field devices 38.

[0021] As shown in Figure 4, a variety of different field devices 38 may be connected to the field device connectors 18 with field wires 44. Typically, each field device connector 18 will include two connectors 18A, 18B, with one being a positive voltage connector 18A and one being a ground connector 18B. Thus, each field device 38 is connected to the base 12 with two wires 44. However, the power and data requirements of each field device 38 may differ from each other in a way that must be accommodated by the base 12 and signal processing module 36. For example, some devices 38A may provide their own power and transmit or receive data within an analog range of 4-20 mADC. Other devices 38B may require power to be supplied from the base 12 in an analog range of 4-20 mADC. Other devices 38C may require power to be supplied in an analog or digital range of 1-5 VDC. The various types of field devices 38 that may be used with the universal

communications module 10 typically conform to industry standards which are well- known. It is common (although not always the case) for the field devices 38 to communicate with analog signals. Thus, one function of the signal processing module 36 is to convert the analog signals to digital data and provide addressing data to allow a central process controller to utilize data from the field devices 38.

[0022] As further shown in Figure 4, each field device connector 18 is associated with a set 14 of pins 46, a fuse 20, and a status light 50 to form a data channel 42 in communication with the signal processing module 36 (and preferably with a respective signal processor 40). In the preferred embodiment, each set 14 of pins 46 is arranged in five rows with three pins 46 in each row for a total of 15 pins 46 in each set 14 (i.e., each channel 42). As shown in Figure 5, a portion of the pins 46 is connected to the respective field device connector 18; another portion of the pins 46 is connected to the power supply connector 22; and another portion of the pins 46 is connected to the respective signal processor 40. Thus, depending on how the pins 46 are interconnected with each other, different arrangements of power and data communication may be provided between the field device 38, power supply 22 and signal processor 40.

[0023] As shown in Figure 12A, one arrangement that may be desirable is for the field device connector 18 to be connected to the signal processor 40 without connecting the field device connector 18 to the power supply connector 22. This arrangement would typically be used where the field device 38 has a separate power supply or a power supply is not needed. This arrangement may be labeled EPD for Externally PowereD. Another possible arrangement is shown in Figure 12B. In this arrangement, the field device connector 18 is connected to the power supply connector 22, but specifically in a way that the ground connectors 22B, 18B of the power supply 22 and the field device connector 18 are directly connected together. The positive connectors 22A, 18A of the power supply 22 and the field device connector 18 are indirectly connected by connecting both connectors 22A, 18A to the signal processor 40. This arrangement may be labeled FPN for Field Power Neutral. Yet another arrangement is shown in Figure 12C. In this arrangement, the positive connectors 22A, 18A of the power supply 22 and the field device connector 18 are directly connected together and the ground connectors 22 B, 18B of the power supply 22 and the field device connector 18 are indirectly connected by connecting both connectors 22B, 18B to the signal processor 40. This arrangement may be labeled FPH for Field Power High. Other arrangements may also be desirable. For example, it may be desirable to adjust a voltage output from the power supply 22 to a particular desired voltage output. For example, in the preferred embodiment, each data channel 42 is provided with a status indicator light 50, which may be an LED 50 that requires a voltage supply within a particular range. Thus, depending on how the pins 46 are interconnected with each other (Figure 5), the voltage from the power supply 22 can be adjusted to suit the power requirements of the LED 50 or another component. These alternative arrangements may be labeled LV for Low Voltage and PIV for High Voltage.

[0024] Various pin 46 connections to achieve the arrangements described above, and others that may be desired, may be accomplished with the pin selectors 52. Preferably, multiple pin selectors 52 are provided with different arrangements of connectors 54 therein to interconnect different pins 46 together in a set 14 of pins 46. In the described examples, it may be desirable to provide six different pin selectors 52A-F, with each being visually labeled as EPD LV 52A, EPD HV 52B, FPN LV 52C, FPN HV 52D, FPH LV 52E and FPH HV 52F. As shown in Figure 1 1 , each pin selector 52A-F has a different arrangement of connectors 54 to connect together different portions of the pins 46 in a respective set 14 of pins 46 (also refer to Figure 5). Thus, the data channels 42 can be separately configurable depending on which pin selector 52 is connected to the set 14 of pins 46. Another advantage is that the field device connector 18 can be completely disconnected from the power supply 22 and/or signal processing module 36 by removing the respective pin selector 52 from the set 14 of pins 46. This may be useful when it is desired to test the field wires 44 or field device 38 without any influence from the power supply 22 or signal processing module 36.

[0025] As shown in Figure 7, the connectors 54 in the pin selector 52 for connecting together pins 46 in the pins sets 14 may be conventional printed circuit board jumper caps 54. In this embodiment, the pin selector 52 may have a housing 56 with a molded plastic top portion 58 and a molded plastic bottom portion 60. The bottom portion 60 may have a cavity 62 to receive a jumper 54 corresponding with one or more of the rows of pins 46. Although not visible in Figure 7, the cavity 62 may be formed such that the jumper 54 is positioned either on the right or the left to engage the middle pin 46 in a row and either the right or left pin 46 and the row.

This may be done by providing ribs 64 (Figure 11 ) such that the jumper caps 54 can only be placed in a particular position to engage specific pins 46. In this case, the bottom portion 60 of the housing 56 may have a different mold shape for each type of pin selector 52 to define the particular connection arrangement of the pin selector 52. As shown in Figure 9, the bottom portion 60 may also have a label 66 for the particular connection arrangement molded into the bottom portion 60. If desired, the top portion 58 may have a single molded shape for all types of pin selectors 52. For a visual marking, the top portion 58 may have a printed identification 68 that matches the particular bottom portion 60 and connectors 54 therein. In the assembled pin selector 52, the top and bottom portions 58, 60 of the housing 56 are permanently snapped together with the jumper caps 54 trapped between the top and bottom housing portions 58, 60. It may be desirable for the pin selectors 52 to have a finger grip 70 that allows the pin selector 52 to be easily grasped to connect and disconnect the pin selectors 52 with the pin sets 14. As shown in Figures 7-8, it may be desirable to provide a visual identification 68 of the type of pin selector 52 on the top of each pin selector 52 to be able to identify the pin selectors 52 when they are connected to the pin sets 14.

[0026] As shown in Figure 8, it may also be desirable to provide a pin selector key 72 for each pin selector 52. The pin selector key 72 is provided with a key surface 74 that mates with a corresponding key surface 76 on a matching pin selector 52. In the embodiment shown, the key surface 74 on the pin selector key 72 may be one or more ribs 74 and the key surface 76 on the pin selector 52 may be one or more slots 76. Although other designs are possible, in the embodiment of Figure 8, there may be three key surfaces 74, 76. In other pin selectors 52 and pin selector keys 72, the corresponding key surfaces 74, 76 may be in different locations or may be different shapes, sizes, etc. As a result, only the type of pin selector 52 that matches the pin selector key 72 (e.g., EPD LV pin selector key 72 and EPD LV pin selector 52) can be inserted into the pin selector key 72. That is, the key surfaces 74 of the pin selector key 72 prevent non-mating pin selectors 52 from being inserted into the pin selector key 72. Preferably, the pin selector keys 72 have a portion 78 that extends up near the top of the corresponding pin selector 52 and a visual identification 80 of the type of matching pin selector 52 is provided thereon. Thus, the user can easily see and match up the pin selector keys 72 and pin selectors 52. It is thus understood that in the described embodiment, there will be six different types of pin selector keys 72 to match the six different types of pin selectors 52.

[0027] In use, the pin selector key 72 preferably has a snap 82 that allows the pin selector key 72 to be snapped onto the base 12 to connect it onto (i.e. , around) one of the pin sets 14 (see also Figure 6). Typically, the placement of the pin selector keys 72 on the pin sets 14 will be determined by the initial design of the control system during setup. The bottom surface of the pin selector key 72 has one or more openings 84 that allow the pins 46 of the pin set 14 to extend up into the pin selector key 72 (Figure 9). A matching pin selector 52 may then be pressed down into the pin selector key 72 and onto the pin set 14 until the pins 46 extend up into the bottom pin holes 86 in the pin selector 52 to engage with the connectors 54 within the pin selector 52. The pin selectors 52 are also provided with a snap 88 (Figure 8) that snaps into the pin selector key 72 to retain the pin selector 52 onto the pin set 14. However, the retention force of the pin selector key snap 82 onto the base 12 is greater than the pin selector snap 88 onto the pin selector key 72. This allows the pin selectors 52 to be pulled out and disconnected from the pin sets 14 without removing the pin selector keys 72 (see, e.g., the pin selector key 72 and pin selector 52 at the fourth position from the right in Figure 6).

[0028] An advantage of this arrangement is that after a communications module 10 has been set up in the field, maintenance people may wish to test the field wires 44 and/or field devices 38 by disconnecting the field device connectors 18 from the power supply 22 and signal processing module 36. In the described embodiment, this may be achieved by pulling out and removing the pin selectors 52. After testing, the pin selectors 52 must be reinstalled onto the pin sets 14 in order to reconnect the power supply 22 and signal processing module 36. However, it is critical that the pins 46 in each pin set 14 be reconnected in the correct arrangement to ensure that the field devices 38 operate correctly and no damage occurs to the field devices 38. The pin selector keys 72 solve this concern, since during testing, the pin selector keys 72 remain on the base 12 connected to the respective pin sets 14. As a result, when the pin selectors 52 are reinstalled, it is only possible to install pin selectors 52 that match the corresponding pin selector keys 72. Thus, it is easy to reconnect the pins 46 in the correct arrangement after testing.

[0029] As shown in Figure 10, is also possible to provide a generic tray 90 to replace the pin selector keys 72 if the key matching function is not needed or desired. Of course, it may also be possible to directly connect the pin selectors 52 onto the pin sets 14 without the pin selector keys 72 or generic tray 90 if desired.

[0030] While preferred embodiments of the inventions have been described, it should be understood that the inventions are not so limited, and modifications may be made without departing from the inventions herein. While each embodiment described herein may refer only to certain features and may not specifically refer to every feature described with respect to other embodiments, it should be recognized that the features described herein are interchangeable unless described otherwise, even where no reference is made to a specific feature. It should also be understood that the advantages described above are not necessarily the only advantages of the inventions, and it is not necessarily expected that all of the described advantages will be achieved with every embodiment of the inventions. The scope of the inventions is defined by the appended claims, and all devices and methods that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein.