Electricity: electrical systems and devices – Housing or mounting assemblies with diverse electrical... – For electronic systems and devices
Reexamination Certificate
1998-11-17
2001-01-09
Gaffin, Jeffrey (Department: 2841)
Electricity: electrical systems and devices
Housing or mounting assemblies with diverse electrical...
For electronic systems and devices
C361S689000, C361S731000, C361S732000, C361S733000, C361S735000, C361S752000, C439S716000, C439S717000, C439S928000, C439S928100
Reexamination Certificate
active
06172875
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to controller assemblies, such as those used in a programmable logic controller (PLC) system, and particularly to a modular component for a PLC system that facilitates attachment and detachment of individual modules, such as I/O modules, processor modules, communication modules and power supplies.
BACKGROUND OF THE INVENTION
Programmable logic controllers are used throughout industry to control and monitor a wide range of machines and other movable components and systems. Conventional PLC systems utilize a plurality of modules, e.g. input/output modules, that are mechanically mounted in a rack system and electronically connected along a back plane. The individual modules can be interchanged or replaced by disconnecting them from the rack and/or back plane. It would be advantageous to eliminate the mounting components, e.g. rack and back plane, and to provide modules that were in an interlocking, modular form.
At least one attempt has been made to construct modules that may be interconnected to each other without the use of a rack or back plane. In this particular embodiment, each module includes a stationary plug and a stationary plug receptacle designed for mating engagement with the stationary plug of a next adjacent module. Additionally, each module includes a housing having a plurality of tongs on one side and a plurality of openings on the opposite side to receive the extended tongs of the next adjacent module. Each module also includes a mounting mechanism for mounting along a DIN rail.
Thus, an individual module can be attached to an adjacent module by moving the individual module along the DIN rail until the tongs and plug connector engage the openings and plug connector of the next adjacent module. Once engaged, locking mechanisms are used to hold the module prongs within the corresponding openings of the next adjacent module.
This configuration does not permit mechanical interlocking of adjacent modules independent of forming an electrical connection between modules. Additionally, the design does not permit the removal of an individual module that is sandwiched between adjacent modules without upsetting the mounting of additional I/O modules. The mechanical interlocking system requires that a module be moved laterally sufficiently far to clear its engagement prongs from the openings of the next adjacent module. To permit this lateral movement, all of the modules positioned on one side of the subject module must be moved to provide sufficient clearance for removal and/or insertion of the subject module. Once the subject module is engaged, the string of modules moved out of the way must be reengaged.
It would be advantageous to have a compact, rackless, modular PLC system utilizing modules that could be selectively, mechanically interlocked and yet readily inserted or removed regardless of whether the module was disposed between adjacent modules.
SUMMARY OF THE INVENTION
The present invention features a system for interlocking modules, e.g. input/output modules, of a programmable logic controller. The system includes a plurality of modules for use in a PLC system in which each module includes a first interconnection feature and a second interconnection feature. The first interconnection feature is configured for selective engagement with the second interconnection feature of an adjacent module. Each module also includes a connector plug portion on one side of the module and a corresponding plug portion on the other side of the module. The connector plug portion is designed to provide an electrical interconnection with the adjacent module. Similarly, the corresponding plug portion is configured to receive a connector plug portion from another adjacent module positioned on the other side of the subject module. At least one of the connector plug portion and the corresponding plug portion is mounted for reciprocal movement into and out of electrical connection while the adjacent modules are mechanically interconnected.
According to another aspect of the invention, a PLC module is configured for mounting along a common mounting structure. The PLC module includes an outer housing having a back portion, a front portion, a left side and a right side. The PLC module further includes an attachment mechanism designed to secure the outer housing to the common mounting structure, such that the back portion lies adjacent the mounting structure. Additionally, the module includes a plurality of interconnection features arranged to permit sliding engagement with a pair of adjacent PLC modules that also may be connected to the mounting structure. The interconnection features are disposed adjacent both the left side of the housing and the right side of the housing. Furthermore, the plurality of interconnection features are oriented to permit removal of the PLC module while the pair of adjacent PLC modules remain in position along the mounting structure.
According to a further aspect of the invention, a method is provided for interlocking a plurality of modules in a PLC system. The method includes mechanically locking a first module with a second module. Additionally, the method includes independent formation of an electrical interconnection between the first module and the second module.
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Baran Michael S.
Clemente Joel C.
Gibart Anthony G.
Grosskreuz Paul J.
Hughes Kevin G.
Gaffin Jeffrey
Horn John J.
Rockwell Technologies LLC
Someren Robert A. Van
Vigushin John B.
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