Industrial field controlling device with controller and expansion modules

• US 6,008,985 A
• Filed: 10/04/1996
• Issued: 12/28/1999
• Est. Priority Date: 11/20/1995
• Status: Expired due to Term

• Current Assignee: Schneider Electric Systems USA, Inc. (Schneider Electric SE)
• Original Assignee: The Foxboro Company (Schneider Electric SE)
• Inventors: Lake, Harold, Prentice, David P., Greenup, John, Piper, Charles, Korowitz, Simon
• Primary Examiner(s): Fuller, Benjamin R.
• Assistant Examiner(s): PATEL, JAGDISH C
• Application Number:
  US08/725,741
• Time in Patent Office: 1,180 Days
• Field of Search: 361/686, 361/685, 361/684, 361/724, 361/725, 361/726, 361/727, 361/730, 361/796, 361/799, 361/753, 395/280, 395/281, 395/282, 395/800, 439/76.1, 439/61, 439/928, 364/708.1
• US Class Current: 361/679.32
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/21103 Connect pc to machine, controller, module via PCMCIA
• CPC Class Codes: G05B 2219/25314 Modular structure, modules
• CPC Class Codes: G05B 2219/25322 Stackthrough modules, modules are stacked, no need for backplane
• CPC Class Codes: G05B 2219/25335 Each module has connections to actuator, sensor and to a fieldbus for expansion
• CPC Class Codes: G05B 2219/25336 Cascaded modules, one module connects to other, I-O, computing expansion
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/33179 Pcmcia
• CPC Class Codes: G05B 2219/33273 DCS distributed, decentralised controlsystem, multiprocessor
• CPC Class Codes: G05B 2219/33279 Expansion by using secondary access to each module, extension module
• CPC Class Codes: G05B 2219/34436 Interface circuit build into connector, dongle
• CPC Class Codes: H01R 9/2658 with built-in data-bus connection
• CPC Class Codes: Y10S 439/928 Modular electrically interengaging parts, e.g. stove with replaceable heating elements formed on coupling parts

Abstract

An industrial computing device includes a field mountable primary housing having a removable side cover to facilitate expansion. Within the primary housing there is a head board having a processor on one side. On the opposite side, there is an expansion connector adapted to receive an expansion board and at least one peripheral connector, which is coupled to the processor within the housing. The peripheral connector receives at least one PCMCIA card such that the PCMCIA card is also within the housing when plugged into the peripheral connector. The expansion board includes at least one more peripheral connector to receive at least one more PCMCIA card. The peripheral connector, the expansion connector and the side cover are oriented orthogonal to a mounting plane of the computing device. The primary housing can also include a removable front cover, which together with a top or bottom portion of the primary housing, provides an aperture for flush-mounting an I/O device in the form of an internal dongle. The dongle can include a rear cable that connects to the PCMCIA card or other device within the housing, a front connector for coupling to a field device, and a circuit coupling the connector and the cable.

Claims

1. An expandable field controller, comprising:

a housing, including at least one removable side cover to facilitate expansion, and a DIN rail mount adapted to mount the housing on a DIN rail and to provide a ground connection;

a ground bus within said housing electrically coupled to the DIN rail mount;

a processor within the housing;

a peripheral connector within the housing that is electrically coupled to the processor for receiving a PCMCIA card;

an expansion connector on a head board within the housing adapted to receive a mating expansion connector on an expansion board which includes at least one more peripheral connector adapted to receive at least one more PCMCIA card, wherein the peripheral connector, the expansion connector, the primary housing, and the at least one removable side cover are oriented orthogonal to a mounting plane provided by said DIN rail.

2. An expansion module for a modular, field mountable industrial computing system that includes a primary module having a head board within a primary housing which mounts to a DIN rail through a DIN rail mount, the head board including a processor, a peripheral connector for receiving at least one PCMCIA card, and an expansion connector on one side for connecting to the expansion module, the expansion module comprising:

an expansion housing;

an expansion ground bus within the expansion housing which electrically connects to the DIN rail mount when the expansion module is connected to the primary module;

an expansion board within the expansion housing;

an expansion peripheral connector on the expansion board adapted to receive at least one PCMCIA card;

a first expansion connector on one side of the expansion board and electrically coupled to the expansion peripheral connector; and

a second expansion connector on an opposite facing side of the expansion board, wherein the primary module is expandable by connecting the first expansion connector to the expansion connector of the primary module such that the expansion board is parallel to the head board, and is further expandable by connecting the second expansion connector to the first expansion connector of a similarly configured second expansion module such that the expansion board of each expansion module is parallel to the other and with the head board, and additional similarly configured expansion modules can be successively mounted onto the preceding expansion module in a parallel arrangement with the expansion connector, the first expansion connectors, and the second expansion connectors electrically coupled to each other and providing a communication bus for the system.

3. A modular expandable industrial computing system, including a primary module adapted to operatively couple to one or more similarly configured expansion modules, the primary module comprising:

a field mountable primary housing, including at least one removable side cover on a first facing side to facilitate expansion to one of the expansion modules, and a DIN rail mount on a rear side which mounts to a DIN rail and provides a ground connection;

a primary ground bus within the primary housing that is electrically connected to the DIN rail mount; and

a head board oriented parallel to the first facing side within the primary housing and having thereon;

a processor;

at least one primary peripheral connector electrically coupled to the processor and adapted to receive at least one PCMCIA card such that when the PCMCIA card is plugged into the primary peripheral connector, the PCMCIA card is within the primary housing; and

an expansion connector on the first facing side of the head board and that is electrically coupled to the processor, wherein the expansion connector is adapted to receive a first expansion connector on an expansion board in an expansion module, the expansion board including at least one more peripheral connector being adapted to receive at least one more PCMCIA card and a second expansion connector on a side opposite the first expansion connector and similarly configured to the expansion connector on the head board, wherein the peripheral connector, the expansion connector, and the at least one removable side cover are oriented orthogonal to a plane of the DIN rail when the primary housing is mounted thereto, and wherein the expansion modules and the primary module are structured such that a first one of the expansion modules can be mounted onto the primary module and each additional expansion module can be successively mounted onto the preceding expansion module in a parallel arrangement with the expansion connector, the first expansion connectors, and the second expansion connectors electrically coupled to each other and providing a communication bus for the computing system.

4. An industrial computing device, comprising:

a field mountable housing, including a primary housing with at least one removable side cover to facilitate expansion;

a processor being internal to said primary housing;

at least one peripheral connector adapted to receive at least one PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector, said PCMCIA card is internal to said primary housing, said peripheral connector being electrically coupled to said processor;

an expansion connector adapted to receive an expansion board which includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card; and

said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover being oriented orthogonal to a mounting plane of said industrial computing device, wherein said at least one removable side cover includes a first removable side cover being structured and arranged to provide access to said expansion connector from a first lateral side of said primary housing, wherein said at least one removable side cover further includes a second removable side cover structured and arranged to provide access to said processor from a second lateral side of said primary housing, and wherein said second removable side cover includes a DIN rail mount on a rear side structured and arranged to mount said primary housing to a DIN rail, said DIN rail mount being adapted to electrically connect to a ground bus within said primary housing with said first side cover coupled to said primary housing.

5. The industrial computing device of claim 4, further comprising an expansion module which includes said expansion board in an expansion housing, said expansion module being mechanically coupled between said primary housing and said first removable side cover and being oriented orthogonal to said mounting plane of said industrial computing device, each of said primary housing and said expansion housing including I/O structure for mounting at least one I/O connector integral with said primary housing and said expansion housing, respectively.

6. The industrial computing device of claim 5, wherein said expansion module further includes a second expansion connector adapted to receive a second expansion board in a second expansion module, said second expansion board including at least one more peripheral connector being adapted to receive at least one more PCMCIA card.

7. An industrial computing device, comprising:

a field mountable housing, including a primary housing with at least one removable side cover to facilitate expansion, and I/O structure for mounting at least one I/O connector integral with said primary housing;

a processor being internal to said primary housing;

at least one peripheral connector adapted to receive at least one PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector, said PCMCIA card is internal to said primary housing, said peripheral connector being electrically coupled to said processor;

an expansion connector adapted to receive an expansion board which includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card, wherein said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover are oriented orthogonal to a mounting plane of said industrial computing device; and

said I/O connector which comprises an internal dongle, said dongle including;

a body including connective structure being arranged to removably attach the body to said primary housing; and

a circuit assembly, including an exterior connector on the body for electrically connecting to an external electronic device, a dongle circuit, which includes a circuit board attached to the body, being electrically coupled to the external connector through the body, an electronic cable having a first end electrically coupled to the dongle circuit, and a second end including a connector being structured and arranged to connect to an electronic component within the primary housing.

8. The industrial computing device of claim 7, wherein the dongle circuit includes at least one of a passive circuit and an active circuit.

9. The industrial computing device of claim 7, wherein the circuit board is attached to an interior portion of the body which is internal to the primary housing when the body is attached to the primary housing.

10. The industrial computing device of claim 7, further including said PCMCIA card inserted in said at least one peripheral connector, wherein said electronic component within the primary housing is said PCMCIA card.

11. The industrial computing device of claim 7, wherein said I/O structure includes one of a socket structure and a plug structure adapted for connecting with said connective structure.

12. The industrial computing device of claim 11, wherein the one of a socket structure and a plug structure comprises a male faston-type connector.

13. An industrial computing device, comprising:

a field mountable housing, including a primary housing with at least one removable side cover to facilitate expansion, I/O structure for mounting at least one I/O connector integral with said primary housing, a DIN rail mount on a rear side structured and arranged to mount said primary housing to a DIN rail, and a ground bus being electrically coupled to said DIN rail mount to electrically couple to said DIN rail, said I/O structure including a ground connector electrically coupled to said ground bus;

a processor being internal to said primary housing;

at least one peripheral connector adapted to receive at least one PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector, said PCMCIA card is internal to said primary housing, said peripheral connector being electrically coupled to said processor;

an expansion connector adapted to receive an expansion board which includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card, wherein said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover are oriented orthogonal to a mounting plane of said industrial computing device; and

said I/O connector which comprises an internal dongle, said dongle including;

a body including connective structure being arranged to removably attach the body to said primary housing; and

a circuit assembly, including an exterior connector on the body for electrically connecting to an external electronic device, a dongle circuit, which includes a circuit board attached to the body, being electrically coupled to the external connector through the body, an electronic cable having a first end electrically coupled to the dongle circuit, and a second end including a connector being structured and arranged to connect to an electronic component within said primary housing, wherein said ground connector is adapted to electrically connect to said connective structure of said dongle within said primary housing.

14. The industrial computing device of claim 13, wherein the ground connector comprises a male faston-type connector.

15. An industrial computing device, comprising:

a field mountable housing, including a primary housing with at least one removable side cover to facilitate expansion and I/O structure for mounting at least one I/O connector integral with said primary housing, wherein said I/O structure includes a male plug electrically coupled to a ground bus within said primary housing, said plug being structured and arranged to engage with a socket provided in said I/O connector when said I/O connector is mounted to said primary housing;

a processor being internal to said primary housing;

at least one peripheral connector adapted to receive at least one PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector, said PCMCIA card is internal to said primary housing, said peripheral connector being electrically coupled to said processor;

an expansion connector adapted to receive an expansion board which includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card; and

said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover being oriented orthogonal to a mounting plane of said industrial computing device.

16. The industrial computing device of claim 15, wherein said I/O structure further includes a lid being provided with a bead which engages with mating structure provided on said body portion of said I/O connector when said I/O connector is mounted to said primary housing.

17. The industrial computing device of claim 16, wherein said lid is articulated from said primary housing to provide access to said I/O connector.

18. An industrial computing device, comprising:

a field mountable housing, including a primary housing with first and second side covers coupling to opposite lateral sides of said primary housing, a removable front cover, a lid on one of a top end and a bottom end of said primary housing, said lid and said front cover providing a recess for an I/O connector;

a head board being internal to said housing, including a processor on a first side of said headboard being accessible by removing said first side cover, and a peripheral connector on a second side of said head board adapted to receive a PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector said PCMCIA card is internal to said housing and electrically coupled to said processor;

a ground bus within said housing including a connector structured and arranged to couple to a body of said I/O connector when mounted in said recess; and

said peripheral connector, said primary housing and said first and second side covers being oriented orthogonal to a mounting plane of said industrial computing device.

19. The industrial computing device of claim 18, wherein said headboard further includes a second peripheral connector being adapted to receive a second PCMCIA card such that when said second PCMCIA card is plugged into said second peripheral connector said second PCMCIA card is aligned in a plane parallel to said first mentioned PCMCIA card and is electrically coupled to said processor, and wherein said housing further includes a second lid on the other of the top end and the bottom end of said primary housing, said second lid and said front cover providing a second recess for a second I/O connector, said second I/O connector having a cable with a connector at a free end adapted to connect to said second PCMCIA card.

20. The industrial computing device of claim 18, wherein said head board further includes a first type of expansion connector on said second side being coupled to said processor, said industrial computing device being expandable by coupling to one or more expansion modules, each expansion module comprising:

an expansion housing adapted to connect between said primary housing and said second side cover, said expansion housing including a removable front cover and a lid at one of a top and bottom end, said lid and said front cover providing a recess for an I/O connector;

an expansion board within said expansion housing, including a second type of expansion connector on a first side structured and arranged to connect to said first type of expansion connector, another of said first type of expansion connector being on a second side for connecting to an expansion board of another of said expansion modules, and at least one expansion peripheral connector adapted to receive an expansion PCMCIA card such that when said expansion PCMCIA card is plugged into said expansion peripheral connector said expansion PCMCIA card is internal to said expansion housing and is capable of being coupled to said processor via connecting said second type of expansion connector on said expansion board to said first type of expansion connector on said head board; and

an expansion ground bus being structured and arranged to electrically couple to said first mentioned ground bus when said expansion module is coupled to said industrial computing device, said expansion ground bus including a connector structured and arranged to couple to a body of said expansion I/O connector when mounted in said recess of said expansion housing.

21. An industrial computing device, comprising:

a field mountable housing, including a primary housing with at least one removable side cover to facilitate expansion, and a front cover which includes connective elements adapted to snap in and out of engagement with mating connective elements provided within said primary housing;

a processor being internal to said primary housing;

at least one peripheral connector adapted to receive at least one PCMCIA card such that when said PCMCIA card is plugged into said peripheral connector, said PCMCIA card is internal to said primary housing, said peripheral connector being electrically coupled to said processor wherein said front cover is structured and arranged to open to provide access to said peripheral connector through a front end of said primary housing;

an expansion connector adapted to receive an expansion board which includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card; and

said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover being oriented orthogonal to a mounting plane of said industrial computing device.

22. The industrial computing device of claim 21, wherein said connective elements comprise brackets, and said mating connective elements comprise stand-offs.

23. The industrial computing device of claim 22, wherein said stand-offs couple to said at least one removable side cover.

24. The industrial computing device of claim 22, wherein said stand-offs are supported from said primary housing by a ground bus within said housing.

25. The industrial computing device of claim 22, wherein said stand-offs provide support for a head board on which said processor is mounted.

26. The industrial computing device of claim 22, wherein:

said at least one removable side cover includes a first removable side cover being structured and arranged to provide access to said expansion connector from a first lateral side of said primary housing, and a second removable side cover being structured and arranged to provide access to said processor from a second lateral side of said primary housing;

said industrial computing device being expandable by coupling to one or more expansion modules, each expansion module comprising said expansion board within an expansion housing, said expansion housing being adapted to connect between said primary housing and said second side cover, said expansion housing including a removable front cover; and

said expansion board includes a second expansion connector on a first side structured and arranged to connect to said first mentioned expansion connector, a third expansion connector structured similar to said first mentioned expansion connector being on a second side for connecting to an expansion board of another of said expansion modules, and at least one expansion peripheral connector adapted to receive an expansion PCMCIA card such that when said expansion PCMCIA card is plugged into said expansion peripheral connector said expansion PCMCIA card is internal to said expansion housing and is capable of being coupled to said processor via connecting said second type of expansion connector on said expansion board to said first type of expansion connector on said head board.

27. A method of computer controlling an industrial process, comprising:

providing an expandable field controller being mounted on a DIN rail, said field controller including a primary housing with at least one removable side cover to facilitate expansion, within said primary housing there being a processor, a PCMCIA card plugged into a peripheral connector that is electrically coupled to said processor, an expansion connector adapted to receive an expansion board that includes at least one more peripheral connector being adapted to receive at least one more PCMCIA card, said peripheral connector, said expansion connector, said primary housing and said at least one removable side cover being oriented orthogonal to a mounting plane provided by said DIN rail;

coupling a ground bus within said primary housing to said DIN rail;

electrically coupling an industrial process instrument to said PCMCIA card;

at least one of monitoring and controlling said industrial process instrument with said expandable field controller.

28. The method of claim 27, wherein said electrically coupling an industrial process instrument to said PCMCIA card includes:

providing an I/O connector comprising a body, a cable extending from one end of the body and an electrical connector mounted on an opposite end of said body;

coupling the cable to the PCMCIA card;

mounting the body integral with said primary housing; and

coupling said industrial process instrument to said electrical connector.

29. The method of claim 28, wherein said body includes a ground connector and wherein said mounting the body integral with said primary housing includes coupling said ground connector to said ground bus.

30. A method of assembling an industrial computing device, comprising:

providing a field mountable housing that provides a recess and that includes a primary housing and at least one removable side cover to facilitate expansion, wherein a processor, at least one peripheral connector, and an expansion connector are each mounted to a head board that is internal to said primary housing, said peripheral connector and said expansion connector each being electrically coupled to said processor;

mounting said primary housing such that said head board, said peripheral connector, said expansion connector, and said primary housing are oriented orthogonal to a mounting plane of said industrial computing device;

plugging a PCMCIA card into said peripheral connector such that said PCMCIA card is internal to said primary housing and oriented parallel with said primary housing; and

electrically coupling between said PCMCIA card and an industrial process instrument, including integrally mounting an I/O connector to said field mountable housing in said recess, and coupling a cable extending from a rear end of said I/O connector to said PCMCIA card, wherein integrally mounting an I/O connector in said recess includes coupling said I/O connector to a ground bus provided within said primary housing.

31. The method of claim 30, further comprising mounting said field mountable housing to a DIN rail, and connecting said ground bus to said DIN rail.

32. The method of claim 30, further comprising:

mechanically coupling an expansion module between said primary housing and said removable side cover, wherein said expansion module includes an expansion board in an expansion housing, an expansion peripheral connector and a mating expansion connector being mounted on said expansion board, an expansion PCMCIA card being plugged into said expansion peripheral connector, said expansion board, said expansion housing and said expansion PCMCIA card each being oriented orthogonal to said mounting plane, said mechanical coupling including connecting said mating expansion connector to said expansion connector such that said expansion PCMCIA card becomes electrically coupled to said processor; and

electrically coupling between said expansion PCMCIA card and another industrial process instrument.

33. The method of claim 32, wherein said expansion module further includes a second expansion connector located on said expansion board on a side opposite the mating expansion connector, said method further comprising mechanically coupling a second expansion module between said first mentioned expansion module and said removable side cover, by plugging a second mating expansion connector located in said second expansion module into said second expansion connector in said first mentioned expansion module.

34. The method of claim 32, wherein said field mountable housing provides a first recess, wherein said electrically coupling between said PCMCIA card and said industrial process instrument includes integrally mounting a first I/O connector to said field mountable housing in said first recess, and coupling a cable extending from a rear end of said first I/O connector to said PCMCIA card, and wherein said expansion housing provides a second recess, wherein said electrically coupling between said second PCMCIA card and said second industrial process instrument includes integrally mounting a second I/O connector to said expansion housing in said second recess, and coupling a cable extending from a rear end of said second I/O connector to second PCMCIA card.

35. A method of assembling an industrial computing device, comprising:

providing a field mountable housing that includes a primary housing and at least one removable side cover to facilitate expansion, said primary housing providing a first recess, wherein a processor, at least one peripheral connector, and an expansion connector are each mounted to a head board that is internal to said primary housing, said peripheral connector and said expansion connector each being electrically coupled to said processor;

mounting said primary housing such that said head board, said peripheral connector, said expansion connector, and said primary housing are oriented orthogonal to a mounting plane of said industrial computing device;

plugging a PCMCIA card into said peripheral connector such that said PCMCIA card is internal to said primary housing and oriented parallel with said primary housing;

electrically coupling between said PCMCIA card and an industrial process instrument;

mechanically coupling an expansion module between said primary housing and said removable side cover, wherein said expansion module includes an expansion housing that provides a second recess, an expansion board within the expansion housing, an expansion peripheral connector and a mating expansion connector being mounted on said expansion board, an expansion PCMCIA card being plugged into said expansion peripheral connector, said expansion board, said expansion housing and said expansion PCMCIA card each being oriented orthogonal to said mounting plane, said mechanically coupling including connecting said mating expansion connector to said expansion connector such that said expansion PCMCIA card becomes electrically coupled to said processor; and

electrically coupling between said expansion PCMCIA card and another industrial process instrument, wherein electrically coupling between said PCMCIA card and said industrial process instrument includes integrally mounting a first I/O connector to said field mountable housing in said first recess, and coupling a cable extending from a rear end of said first I/O connector to said PCMCIA card, and wherein said electrically coupling between said second PCMCIA card and said second industrial process instrument includes integrally mounting a second I/O connector to said expansion housing in said second recess, and coupling a cable extending from a rear end of said second I/O connector to second PCMCIA card, wherein integrally mounting said first I/O connector in said recess includes coupling said first I/O connector to a ground bus provided within said primary housing, and wherein integrally mounting said second I/O connector in said recess includes coupling said second I/O connector to a ground bus provided within said expansion housing, said ground bus in said primary housing being connected to said ground bus in said expansion housing.

36. The method of claim 35, further comprising mounting said field mountable housing and said expansion housing to a DIN rail with a DIN rail mount, and connecting said ground buses in said primary housing and said expansion housing to said DIN rail.