KR102014691B1 - Remote input-output apparatus for industrial controllers with duplicated power and compler module - Google Patents

Abstract

A remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention is a communication bus connecting redundant communication between a coupler module and a power module, by connecting communication of a module constituting the industrial controller Activated coupler module for monitoring the first communication busbar and the second communication busbar, the second communication busbar through the communication bus, the error of the remaining coupler module and the two power modules, and manages the first communication busbar and the second communication busbar And the remaining coupler module for monitoring for faults in the active coupler module via the communication bus.

Description

REMOTE INPUT-OUTPUT APPARATUS FOR INDUSTRIAL CONTROLLERS WITH DUPLICATED POWER AND COMPLER MODULE}

The present invention relates to an input / output device employed in an industrial controller, and more particularly, to a remote input / output device of an industrial controller having a coupler module.

An input / output module of an industrial controller such as a PLC has a configuration in which a bus of the controller is extended, and the input / output module enables a plurality of connections through a plurality of input / output ports. In particular, a controller such as a fieldbus may be connected to various external devices such as a sensor, a loop controller, a programmable logic controller (PLC), a motor, and a valve through an input / output module to exchange electrical signals.

Remote IO is a device that couples a coupler (Coupler), a communication module, and connects I / O devices, such as sensors and actuators, to an industrial controller such as a PLC through communication such as Ethernet. Remote I / O devices are usually equipped with a coupler and a power module, and have a function of extending a common bus of a PLC through a module structure.

The power module of the remote input / output device is designed to supply enough power for sufficient scalability to be connected to a common bus. For example, it can support up to 10A for DC voltages of 12V and 5V.

However, in the process of connecting a sensor or actuator to a remote input / output device, a contact contact may be damaged or a short circuit may occur due to a failure of the connected devices, and in this process, the power module may be damaged or the operation may stop. have.

In addition, since the coupler is a key component that connects to a main controller such as a PLC of various devices connected to the input / output device, a failure of the coupler causes a serious failure that all devices are disconnected from the main controller.

Republic of Korea Patent Application Publication No. 10-2006-0106245

The problem to be solved by the present invention is to provide a remote input and output device of the industrial controller that can prevent the failure due to communication error and power failure in the process of operating an industrial controller connected to a plurality of expansion input and output modules.

A remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention connects the communication of a coupler module and a communication module for monitoring the power module, and connects the communication of a module constituting the industrial controller. Activated coupler module for monitoring the first communication busbar and the second communication busbar, the second communication busbar through the communication bus, the error of the remaining coupler module and the two power modules, and manages the first communication busbar and the second communication busbar And the remaining coupler module for monitoring for faults in the active coupler module via the communication bus.

If an error occurs in the activation coupler module, the remaining coupler module is replaced with the activation coupler module to manage the first communication busbar and the second communication busbar to perform communication.

The active power module supplies power to two coupler modules and adjacent expansion I / O modules via a power busbar. At this time, when the activating power module is switched, the remaining power module replaces the activating power module and supplies power through the power bus bar.

The active coupler module monitors the active power module and, in the event of a fault, replaces the active power module with the remaining power module. The remaining coupler module, which is replaced and activated according to the fault of the active coupler module, monitors the two power modules through the communication bus and replaces the failed power module with another power module. The failed and replaced coupler module monitors the replaced active coupler module via the communication bus.

The activation coupler module activates any one communication busbar among the first communication busbar and the second communication busbar, which are all common buses, to connect communication with the main controller. If an error occurs in the activated communication busbar, the activation coupler module substitutes another communication busbar to perform communication.

The remote input / output device of an industrial controller having a redundant power supply and coupler module may have a structure in which each module is coupled through a separate slot module as well as a structure in which each module is coupled through a DIN rail.

The slot module is composed of two coupler module slots for coupling the coupler module, two power module slots for coupling the power module, and side input / output terminals for connecting the communication busbar and the power busbar with adjacent expansion I / O modules.

In the remote input / output device of an industrial controller having a redundant power supply and coupler module according to the present invention, two coupler modules and an activation module among the two power modules may be selected by a user or may be determined according to the order of the modules.

According to an embodiment of the present invention, a remote input / output device of an industrial controller having a redundant power supply and coupler module is used to detect a module in which two coupler modules and two power modules perform mutual monitoring through an internal communication bus. It can be replaced by another module to prevent the failure of the industrial controller.

1A is a perspective view illustrating an embodiment of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to the present invention.
1B is a diagram illustrating an internal connection structure of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.
2A and 2D are diagrams for describing a process of performing an operation of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.
3 is a view illustrating a communication busbar structure of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.
Figure 4 is a block diagram showing another example of a remote input and output device of an industrial controller having a redundant power supply and coupler module according to the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Terms and words used herein are terms selected in consideration of functions in the embodiments, and the meaning of the terms may vary according to the intention or custom of the invention. Therefore, the terminology used in the embodiments to be described later, according to the definition when specifically defined in the present specification, if there is no specific definition should be interpreted as meaning generally recognized by those skilled in the art.

1A is a perspective view illustrating an embodiment of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to the present invention.

1B is a diagram illustrating an internal connection structure of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.

1A and 1B, the remote input / output device 100 of an industrial controller having a redundant power supply and coupler module according to the present invention includes disconnection and failure through a pair of coupler modules and a pair of power modules. In response to various error conditions, connected I / O devices are prevented from being disconnected from the main controller.

The remote input / output device of an industrial controller having a redundant power supply and coupler module according to the present invention includes a first coupler module 110, a second coupler module 120, a first power module 130, and a second power module ( 140). And as an example, the first coupler module 110, the second coupler module 120, the first power module 130 and the second power module 140, each of the separable module via a DIN rail (Din Rail) It may have a form coupled to the side, it may have a form coupled through a separate slot module.

In addition, the remote input and output device of the industrial controller having a redundant power supply and coupler module according to the present invention can be extended by additionally connecting the expansion input and output module 20 in the lateral direction.

The first coupler module 110, the second coupler module 120, the first power module 130, and the second power module 140 are each formed in a replaceable module form. Accordingly, the first coupler module 110, the second coupler module 120, the first power module 130, and the second power module 140 may replace only the failed module, and the module may be replaced if necessary. Do.

The first coupler module 110 and the second coupler module 120 transfer data (signal) received from the main controller that centrally controls the industrial controller system to the connected input / output module. The signal transfer function of the first coupler module 110 and the second coupler module 120 includes the functions of a general coupler for connecting between different communication interfaces.

The first coupler module 110 and the second coupler module 120 include communication connectors 115 and 116 for communication connection with the main controller. In the example of FIG. 1A and FIG. 1B, two communication connectors are provided in one coupler, and the kind of communication connector is equipped with LAN connector. However, the number and types of the communication connectors shown in FIGS. 1A and 1B are not limited thereto, but only for one embodiment. The communication connectors 115 and 116 may be freely provided with one or more communication connectors according to the configuration and conditions of the industrial controller, and various communication interface ports including serial ports and parallel ports as well as LAN connectors may be used depending on the communication environment. have.

The first power module 130 and the second power module 140 convert the power of the external power source and supply the converted power to the connected input / output module and the coupler 110 and 120. For example, the first power module 130 and the second power module 140 may convert the supplied AC power into DC power of 12V / 5V 10A and supply the same.

The first coupler module 110, the second coupler module 120, the first power module 130, and the second power module 140 are connected through the communication bus 170 to communicate with each other. The communication bus 170 is not connected to the expansion input / output module 20 except for the first coupler module 110, the second coupler module 120, the first power module 130, and the second power module 140. .

The first power module 130 and the second power module 140 are connected to the power bus bar 160, and the first coupler module 110 and the second coupler module 120 through the power bus bar 160. And supply power to the expansion input / output module 20. In this case, the power bus bar 160 is not formed as one bus bar, but has a form in which bus bars provided in each module are connected in a lateral direction. Therefore, the coupler module, the power module, and the expansion input / output module can be replaced separately.

The first communication bus bar 151 and the second communication bus bar 152 are physically independent of each other, and are connected to all modules (coupler module, power module and expansion input / output module) constituting the industrial controller.

The first coupler module 110 and the second coupler module 120 are connected to the first communication bus bar 151 and the second communication bus bar 152, and the first communication bus bar 151 and the second communication. The bus bar 152 communicates with the expansion input / output module 20 to transmit and receive data (signal). Additionally, the first coupler module 110 and the second coupler module 120 may be connected to the first power module 130 and the second power module 140 through the first communication bus bar 151 and the second communication bus bar 152. ) Can be connected. In this case, the two communication busbars 151 and 152 are not formed as one busbar but have a form in which busbars provided in each module are connected in a lateral direction. Therefore, the coupler module, the power module, and the expansion input / output module can be replaced separately.

Operation of the remote input and output device 100 of the industrial controller having a redundant power supply and coupler module according to the present invention is as follows.

First, either coupler module of two coupler modules 110 and 120 is activated. One of the two power modules 130 and 140 is activated. However, the activation here means that the activated coupler module and the power module are in charge of the main communication function and the main power supply, respectively, and do not mean that the remaining coupler module and the power module do not operate. Modules not selected as an active coupler module and an active power module are also not responsible for the communication and power supply with the I / O modules that make up the industrial controller.

The activated coupler module manages and uses the first communication bus bar 151 and the second communication bus bar 152, which are all common buses. On the other hand, the remaining coupler module is activated except for the first communication busbar 151 and the second communication busbar 152 which are all common buses. That is, the remaining coupler modules are inactive only for the first communication bus bar 151 and the second communication bus bar 152, and perform the remaining functions and communication.

In this case, the criterion for selecting the activation module may be selected by setting and manipulation of the user, and may be freely set according to the order in which the modules are combined or the position in which the modules are combined.

The activated power module supplies power to both the first coupler module 110 and the second coupler module 120 through the power bus bar 160 and also to the connected expansion input / output module 20. The remaining power module is also activated in case the power supply fails and power is not supplied.

As an example, the first power module 130 and the second power module 140 connected to the same power busbar 160 operate virtually both to supply power through the power busbar 160 but with higher power. The power module for supplying the power supply is exclusively supplied through the power bus bar 160 as the activated power module. If a problem occurs or is transferred to an active power module that was supplying higher power, it is replaced by the power from the remaining power modules. At this time, the activated coupler module may monitor both power modules, such that the remaining power modules supply the same power as the activated power module.

The activated coupler module performs a communication function between the main controller and the expansion input / output module 20 that controls the entire industrial controller through one of the two communication busbars 151 and 152. The activated coupler module then monitors the status of the remaining coupler modules and both power modules (both active and the remaining power modules) via the communication bus 170. In addition, the remaining coupler module mutually monitors the state of the coupler module activated via the communication bus 170.

If the remaining coupler module recognizes that a problem occurs in the active coupler module, the remaining coupler module is switched to manage the first communication busbar 151 and the second communication busbar 152 which are the entire common buses, thereby industrializing. It is in charge of communication of the whole controller.

2A and 2D are diagrams for describing a process of performing an operation of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.

2A illustrates a process of performing an operation when the first coupler module 110 and the first power module 130 are activation modules. The first power module 130, which is an active power module, converts externally supplied power into power corresponding to a module constituting the industrialization controller and supplies the power through the power bus bar 160. In addition, the second power module 140 also performs external power conversion. In this case, although the first power module 130 and the second power module 140 both perform power conversion, the module producing higher power allows the power module to supply power through the power bus bar 160 to the activation module.

The main controller A 51 and the main controller B 52 are systems for centrally controlling the industrial controller, and the two main controllers 51 and 52 transmit the same data in duplicate by performing redundancy communication. In addition, the first coupler module 110 configured as an active coupler manages the first communication bus bar 151 and the second communication bus bar 152 which are all common buses, and connects the communication with the main controller A 51. .

The first coupler module 110 activates the first communication bus bar 151 to connect communication with the expansion input / output module 20. In addition, the first coupler module 110 monitors the states of the first communication bus bar 151 and the second communication bus bar 152 so that when an error occurs in the activated first communication bus bar 151, the second communication is performed. Activate busbar 152 to replace first communication busbar 151.

The first coupler module 110, which is an activation module, monitors an error by monitoring a state of the second coupler module 120, which is the remaining module. The first coupler module 110, which is an activation module, monitors the states of the first power module 130 and the second power module 130 to monitor errors.

The other module, the second coupler module 120, monitors an error by monitoring the state of the first coupler module 110, which is an activation module. That is, the first coupler module 110 and the second coupler module 120 continuously monitor the state of each other.

In this case, monitoring and communication between the coupler modules 110 and 120 and the power modules 130 and 140 except for the expansion input / output module 20 are performed through the communication bus 170.

The first coupler module 110, which is an activation module, activates any one communication busbar among the first communication busbar 151 and the second communication busbar 152. In the example of FIG. 2A, the first coupler module 110 activates the first communication bus bar 151 to relay communication between the main controller A 51 and the input / output module 20. The first coupler module 110 continuously monitors whether the second communication busbar 152 is in an error state.

2B illustrates a process of performing an operation when an error occurs in the first power module 140.

The first power module 130 supplies power to the two coupler modules 110 and 120 and all the expansion input / output modules 20 as an activation module. The first coupler module 110, which is an activation module, continuously monitors the state of the first power module 130. The first power module 130 is automatically switched when an error of a power failure occurs due to a short circuit or short from the power supply line of the first power module 130 itself or the external power supply line. . The first coupler module 110, which is an activation module, detects the switching of the first power module 130 through the communication bus 170. The first coupler module 110 converts the second power module 140 into a main power module according to the automatic switching of the first power module 130.

The second power module 140 converts external power and waits even when the first power module 130 is set as an activation module. Substantially, the first power module 130 and the second power module 140 are simultaneously connected to the power busbar 160, and the power of the power module generating higher power is selectively supplied. Therefore, when the first power module 130 is automatically switched, the power of the second power module 140 is supplied to the two coupler modules 110 and 120 and the expansion input / output module 20. Therefore, even if an error occurs in the first power module 130, power may be supplied to a module constituting the industrial controller through the second power module 140 without interruption of power supply.

2C illustrates a process of performing an operation when an error occurs in the first coupler module 110.

The activated first coupler module 110 and the remaining second coupler module 120 monitor the mutual status via the communication bus 170. In this case, the first coupler module 110 manages and uses communication bus bars 151 and 152 which are all common buses. The second coupler module 120, which is the remaining module, only deactivates the use rights of the communication busbars 151 and 152, which are all common buses, and waits for other functions in an activated state.

When the second coupler module 120 monitors an error of the first coupler module 110, the use right of the communication busbars 151 and 152 is activated, and the first coupler module 110 is deactivated. As a result, when an error occurs in the first coupler module 110, the second coupler module 120 manages the communication bus bars 151 and 152 to maintain communication with the main controllers 51 and 52.

2D illustrates a process of performing an operation after replacing an error-prone first coupler module 110.

When the second coupler module 120 is activated and operated in place of the failed first coupler module 110, the user (or an administrator) moves the failed first coupler module 110 to the new coupler module 200. Replace. When the first coupler module 110 in which an error occurs is replaced by a normal module by a user (or an administrator), the replaced first coupler module monitors an error by monitoring a state of the activated second coupler module 120. That is, the replaced coupler module replaces the previous second coupler module.

3 is a view illustrating a communication busbar structure of a remote input / output device of an industrial controller having a redundant power supply and coupler module according to an embodiment of the present invention.

Referring to FIG. 3, the first communication bus bar 151 and the second communication bus bar 152 are mechanically (physically) completely separated structures, and any one of the first communication bus bar 151 and the second communication bus bar 152 is not affected. It is manufactured not to. Accordingly, the first communication busbar 151 and the second communication busbar 152 may be connected to any one bus due to physical contact damage, short due to physical deformation, and damage due to electrical short. Even if the bar is in a fail state, communication can be performed through one busbar.

Figure 4 is a block diagram showing another example of a remote input and output device of an industrial controller having a redundant power supply and coupler module according to the present invention.

Referring to FIG. 4, the remote input / output device 100 of FIGS. 1A and 1B has a structure in which each module is coupled to the DIN rail. On the other hand, the remote input / output device 400 of FIG. 4 has a form in which two coupler modules and two power modules are coupled through the slot module 410.

The slot module 410 includes two coupler module slots 411 and 412, two power module slots 413 and 414, and a side input / output terminal 415. Two coupler module slots 411 and 412 have a structure in which separate coupler modules are coupled to each other. In addition, two power module slots 413 and 414 have a structure in which separate power modules are coupled to each other.

The activated coupler module and the activated power module may be determined according to the position of the slot, by the setting of the user (administrator), or may be determined according to the order in which the modules are combined.

Power busbars and two communication busbars connected with two coupler modules coupled to two coupler module slots 411 and 412 and two power modules coupled to two power module slots 413 and 414 respectively It is connected to the expansion input / output module through the input / output terminal 415.

Although the present invention has been described in detail with reference to preferred embodiments, the present invention is not limited to the above-described embodiments, and various modifications may be made by those skilled in the art within the scope of the technical idea of the present invention. It is possible.

100: wireless input / output device
110: first coupler module 120: second coupler module
130: first power module 140: second power module
115, 116: communication connector
151: first communication busbar 152: second communication busbar
160: power bus bar 170: communication bus

Claims (11)

Two coupler modules, one of which is activated to be in charge of the main communication function and the other of which is inactive;
Two power modules, one of which is activated to be in charge of the main power supply and the other of which is inactive;
A communication bus which is connected to only two coupler modules and two power modules, but not to the expansion input / output module except for these, and which connects the communication for monitoring the coupler module and the power module;
A first communication bus bar and a second communication bus bar connected to all modules constituting the industrial controller and connecting communication of all modules constituting the industrial controller;
A power bus bar connected to all modules constituting the industrial controller and connecting power to all the modules constituting the industrial controller;
Two coupler module slots to which each of the two coupler modules are coupled; two power module slots to which each of the two power modules are coupled; and side input / output terminals connecting a communication busbar and a power busbar to adjacent expansion I / O modules. A slot module including a coupler module or a power module in which a faulty coupler can be easily replaced;
Including,
The two coupler modules monitor each other for errors through a communication bus, and if an error occurs in an active coupler module, the inactive coupler module is activated to activate an activated communication bus among the first communication bus bar and the second communication bus bar. The main communication function via the bar,
The active coupler module monitors the failure of the two power modules through the communication bus, and if a fault occurs in the active power module, the redundant power and coupler module activates the inactive power module and supplies main power through the power busbar. Remote I / O device for industrial controller with The method of claim 1,
A remote input / output device of an industrial controller having a redundant power supply and coupler module for supplying power to two coupler modules and an adjacent expansion input / output module through a power busbar. delete delete delete The method of claim 1,
A remote input / output device of an industrial controller having a redundant power supply and coupler module for deactivating and replacing a coupler module that is inactive and monitors the coupler module being activated through the communication bus. The method of claim 1,
The active coupler module is a remote input / output device of an industrial controller having a redundant power supply and coupler module that connects communication with the main controller by activating one of the first communication busbar and the second communication busbar, which are all common buses. . The method of claim 7, wherein
An active coupler module is a remote input / output device of an industrial controller having a redundant power supply and coupler module that communicates by replacing another communication busbar when an error occurs in the activated communication busbar. delete The method of claim 1,
The two coupler module and the module activated from the two power module is selected by the user's setting, or a remote input and output device of the industrial controller having a redundant power supply and coupler module determined according to the order of the modules. The method of claim 1,
The first communication bus bar and the second communication bus bar is a remote input and output device of an industrial controller having a redundant power supply and coupler module physically separated from each other.

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