Claims:We Claim,

1. A configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing comprises a communication interface circuit board (3), input devices (sensors), plurality of distributed channels (4) each is configured to connect with sensors (input devices) at one end thereof that generates a power signal and output signal and other end of each distributed channel (4) is connected with said communication interface circuit board (3), plurality of LEDs (6) for indicating power signal and output signals, a trunk line (5) that carry plurality of terminals wires (W1 to Wn) and that is configured to connect with input and output modules of the controller at one end thereof, a network cable (10) and a computer (11) having Supervisory Control and Data Acquisition (SCADA) application;

wherein said communication interface circuit (3) comprises a communication protocol data unit (12) having a central controller (12a), a hole assembly (H) having plurality of contact holes (H1 to Hn) for receiving power signals and output signals from said input devices, a common power track (B’) and a common ground track (C’) for carrying power signal from said hole assembly to said central controller (12a), a signal carrying track (A’) for carrying output signal of each sensor device to said central controller (12a), a terminal assembly (T) having plurality of terminals (T1 to Tn) being connected with terminal wires (W1 to Wn) of said trunk line (5);

characterized in that said communication protocol data unit (12) is configured to receive and transmit data of the output signals through the network cable to said computer (11) for graphical representation of output signals of said sensing devices (sensors) and output devices on said computer through said Supervisory Control and Data Acquisition (SCADA) application.

2. The configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable as claimed in claim 1, wherein said communication protocol data unit (12) is configured to support one of network protocol from Process Automation protocols.

3. The configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable as claimed in claim 1 and 2, wherein said process automation protocols comprises protocols namely AS-i, BSAP, CC, CIP, CAN, ControlNet, DeviceNet, DF-1, DirectNet, EtherCAT,, EGD, EtherNet/IP, Ethernet Powerlink, FINS, fieldbus, HART, HostLink, Interbus, MACRO Fieldbus, MECHATROLINK, MelsecNet, Modbus, Modbus Plus, Modbus RTU or ASCII or TCP, OSGP, Optomux, PieP, Profibus, PROFINET IO, RAPIEnet, Honeywell SDS, SERCOS III, SERCOS, SSCNET, GE SRTP, Sinec H1, SynqNet, TTEthernet and Zigbee.

Dated this on November 17, 2015
, Description:FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION: CONFIGURABLE SYSTEM FOR DISTRIBUTING AND REMOTE MONITORING OF MULTIPLE I/O SIGNALS BY REDUCING CABLE HARNESSING

2. APPLICANT:
(a) NAME : Katlax Enterprises Pvt. Ltd.
(b) NATIONALITY : Indian
(c) ADDRESS : 117-119, Santej-Vadsar Road,
Kalol, Gandhinagar - 382 721
Gujarat, India

3. PREMABLE TO THE DESCRIPTION
PROVISIONAL

The following specification describes the invention. þ COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.

This application is an addition of Indian Application 3170/MUM/2015 which has filling date of August 20, 2015.

Field of the Invention

The present invention relates to a system for carrying and distributing multiple I/O signals though the controller i.e. PLC by reducing cable harnessing and more particularly, it relates to a configurable system for monitoring the distributed I/O signals by communicating said I/O signals with personal digital computer through communication network protocols.

Background of the Invention

Today increasing complexity of machines and systems presents ever greater challenges to companies, even in the wiring between controllers and sensors/actuators. In recent, electrical assemblies are utilized in electrical system where plurality of inputs and outputs are to be connected i.e. automation industries. In many cases, these electrical connections are done by plurality of wires which act as conductors for transmitting an electrical signal from one part of the assembly to another or to external devices. As a general rule, the more complicated the assembly, the greater the number of signals. Consequently, complex assemblies often require a greater number of wires to conduct these signals. To simplify the manufacturing process and improve assembly serviceability, the designer of such an assembly typically organizes the various wires in groups according to their point of origin and their destination. Wires grouped in such a manner make up a fabricated assembly known as a cable harness.
In complex control applications, mostly in automation industries, an industrial controller i.e. PLC have been used that has the facility for input/output (I/O) arrangements which connect the PLC to sensors (inputs) and actuators (outputs). The PLC typically comprises a predetermined number of slots, which are dedicated modules for a single function typically, a multitude of different electrical parts and integrated circuits are used to drive each one of the specific input/output configurations. When users install I/O modules into PLC, they individually wire each point that is being controlled to the specific I/O device. Generally, each point in the module is individually wired to connect the I/O module to the machine interface, and a cable customized to the specifically wired I/O module is utilized. Therefore, to connect different machine interfaces to the same I/O module, typically cable harness is used. The harness may have a set of wires to connect the input and output devices with I/O module of controller.
Such conventional systems, while providing a highly centralized form of control, suffer from various disadvantages. For example, the numerous wires (wire harnessing) that must be connected between the inputs devices and I/O module of controller and output devices often result in large, bulky and complex wiring harnesses. Bulky and/or complex wiring harnesses, for example, increase manufacturing costs, make changes in the system more difficult, and can result in undesirable compromises in the overall system physical design in order to accommodate the wiring harnesses. In addition, it is often very difficult for troubleshooting due to hard wire connection.
Further, said I/O devices are connected with system controller i.e. PLC through the use of individual wire connections via terminal blocks. Terminal blocks usually employ a screw-driven clamp. An electrical wire's insulation is removed from the end, and then the bare wire is slid under the screw-driven clamp. The screw is then tightened to secure the wire under the clamp and effect an electrical connection between the wire and the terminal block. Hence, hand wiring must be performed to in order to effect the interconnection which is quite cumbersome and require labor intensity.
Further, due to the complex wiring, there is a possibility of causing error in connection that may leads to damage to the I/O devices. Hence, in such system, designer and installer are required to give adequate attention to the details of instrumentation wiring during design and installation. Moreover, in automation solution, said wires have to be of different length even when connecting to the same connector position.
In order to alleviate this problem, various kinds of attempt have been done heretofore. One such attempts have been disclosed in U.S. patent US2007255879 that teaches to reduce the cable complexity and also reduces the cumbersomeness in making individual wire interconnection in a system where multiple I/O devices are connected to PLC. Said system comprises an I/O module for interfacing the system controller with external device. According to this system, microprocessor of I/O module receives instruction from controller to sense a particular device.
However, such conventional systems leave some scope of improvements. Said systems are very complex and hence lead to high manufacturing cost. Due to complex wiring, it is very cumbersome to find out find out specific channel if any fault occurs. Hence, in such event, operator needs to go near individual device which may be placed at inaccessible place. Further, sometimes in order to find faulty channel, every wire connections are required to be checked which may take a longer time and extra human effort.
Further, in automation industries, various kinds of industrial control system like SCADA, DCS etc. are communicated with PLC by respective communication protocols for monitoring and control the electrical parameters(like voltage, current, power factor, etc) and controlling if any fault occurs in electrical system with the help of personal computer(PC). PLCs have variety of configurations, including rack mounted Input/Output (I/O) systems. The racks provide mechanical/electrical connection slots for a power supply, central processing unit (CPU) boards, and controlled I/O modules, which provide interfaces to external devices to be controlled. For doing so, automation direct offers high quality, low-capacitance data cables designed with impedances specific for RS-232/RS-422 and RS-485 communication applications in industrial environments. However, in industries deployed in vast area, sometime communication cables of adequate length are required to connect and to extend the distance between the computer and PLC being located in hazardous industrial environment that increases acquisition and implementation costs and eventually maintenance costs. In order to avoid this problem, data transmission lines should always be as short as possible to avoid signal reflections on the line which is not possible in all kinds of automation industries.
It is therefore desirable to invent a device to address above problems and replace the conventional systems.
Object of the Invention
The main object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that is more economical, reliable and provide multi conductor cable harnessing solution by reducing the number of wire connections.
Another object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that is configured to use in a distributed input/output system, having circuits for responding to computer generated signals for the control of a sequence of data transfer operations, including operations that are dependent upon the logic level of signals representing the status of peripheral units.
Further object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that is flexible and saves installation time and reduces potential wiring error.
Yet another object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that reduces the cable complexity involved in making interconnections in control systems.
Yet object of the present invention to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing for reducing the number of custom designed cables and individual wire connections in a system.
One more object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that is compatible to meets the IP67 so that it can be easily install and use in harsh environment.
One more object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that provides visual indication of status of I/O signal and power for ease of monitoring the devices and reducing commissioning and troubleshooting time.
One more object of present invention is to provide a configurable system for distributing and remote monitoring of multiple I/O signals by reducing cable harnessing that provides End to End solution in industrial automation.
Summary of the Invention
The present invention relates to a system for distributing and remote monitoring of multiple i/o signals by reducing cable harnessing comprises a hub having a communication interface circuit board, plurality of distributed channels each is configured to connect with sensors at one end thereof that generates a power signal and output signal and other end of each distributed channel is connected with said communication interface circuit board, plurality of LEDs for indicating power signal and output signals, a trunk line that is configured to connect with input and output modules of the controller at one end thereof, a network cable and a computer having Supervisory Control and Data Acquisition (SCADA) application. Said communication interface circuit comprises a plurality of hole assembly, a plurality of terminal assembly being connected with said trunk line, a common power track and a common ground track for carrying power signal, a signal carrying track for carrying output signal of each sensor device and a communication protocol data unit for performing serial data communication of the output signals through the network cable to said computer for graphical representation of output signals of said sensing devices (sensors) on said computer through the Supervisory Control and Data Acquisition (SCADA) application.

Brief Description of the drawings
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.
Fig. 1 depicts a perspective view of the system according to present invention.
Fig. 2 depicts a schematic diagram of the system according to present invention.
Fig. 3 depicts a schematic diagram of first embodiment of system according to present invention.
Fig. 4 depicts a schematic diagram of second embodiment of system according to present invention.
Fig. 5 depicts a schematic diagram of third embodiment of system according to present invention.
Detailed Description of the Invention
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompany drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

It is to be noted that, in the drawing, identical reference number identify similar element and acts. It is also to be noted that in the embodiments of present invention, PLC (Programmable Logic Control) is employed as a controller. However, the system according present invention is configured to connect with other suitable controllers.

The system according to present invention is configured to carry data to PLC (controller) received from sensing (input) devices and the commands from PLC that are sent to actuating and indicating (output) devices by reducing cable harnessing at PLC. Further, said system is also configured to provide digital data communication by interfacing said signals of I/O devices with personal computer for remotely monitoring the status of each sensing (input) device and output devices.

Now as shown in Fig. 1, the system according to present invention comprises a hub (2), plurality of distributed channel (4), a controller (9), a trunk line (5) that carry plurality of terminal wires (W1 to Wn) (shown in Fig. 2) for transmitting plurality of signals simultaneously to the controller (PLC) (9), a network cable (10) and a personal digital computer (11) having a software of supervisory Control and Data Acquisition (SCADA) application for graphic representation of status of signals associated with the automation system and to control some aspects of system operation by gathering the data from said hub (2) in real time from remote location. The computer (11) is work station, laptop, personal digital assistant (PDA), tablet personal computer (PC) and the like.

It is to be noted that software of said application (SCADA) is selected according to the types of the PLC to be used.

Said hub (2) includes a communications interface circuit board (3) being disposed within its interior space (shown in Fig. 2), a plurality of aperture (not shown) linearly disposed on its front wall (F), each said aperture receives at least one conductive cable or distributed channel (4) such that each distributed channel is electrically connected to said interface circuit board (3), a hole made on rear side (R) thereof wherefrom the trunk line (5) is connected and extended to be connected with said PLC (controller) through industrial standard connector (8), pluralities of LEDs (6) linearly arranged on and protruded from the annular cavities (not shown) opening on the upper wall (U) of the hub (2), a couple of screw-mounting holes (7) made on its upper surface (U) and lower surfaces (not shown) wherein a suitable screw is inserted and extended through the interface circuit board (3) for firmly fixing said circuit board (3) in the hub (2). Said hub (2) is configured to meets the IP67 standard so that it protects said interface circuit board (3) against dust ingress as well as immersion of water so as to can be located in a rugged industrial atmosphere.
Said cables or distributed channels (4) are of different length as per requirement and consist of wires assembly having a signal wire, a power wire and a ground wire that are denoted by A, B and C respectively as shown in Fig. 2. One end of each cable or distributed channel (4) is electrically connected to the interface circuit board (3) through a contact hole assembly (H) in the manner as discussed below. At other end of each distributed channel (4), an industrial standard connector (8) i.e. M12/M8 is secured through which input device i.e. sensor (not shown) is connected so that the sensor can electrically communicate with the interface circuit board (3) through the wire assembly (A, B, C). Each sensor is connected between the power wire (B) and the ground wire (C) and the data output of the sensor that generate output signal is connected to the third wire, signal wire (A). Said power wire (B) and the ground wire (C) carry the power signal of 24 V DC and the signal wire carry output signal generated by the sensor. In this embodiment, only six conductive distributed channels (4) are shown so that at least six input devices are connected, however, the hub (2) is configured to receive any number of inputs devices as per requirement.

In said embodiment 3-wire sensors are utilized as input devices. However, it is to be noted that other kinds of digital devices can be employed as per requirement. It is also contemplated that the input devices may be any suitable type of sensor. For example, the sensor is one from a pressure sensor assembly, a humidity sensor assembly, a force sensor assembly, a pressure switch assembly, a light sensor assembly, a gas concentration sensor assembly, a magnetic or electrical field sensor assembly, a conductivity sensor assembly, or another other suitable sensor assembly. In this embodiment, only six conductive distributed channels (4) are shown so that at least six input devices were connected, however, the hub (2) is configured to receive any number of inputs devices as per requirement.

Said communications interface circuit board (3) is configured to perform serial data communication for transmitting combined digital signals (power signals and data output signals) being produced by input devices (sensors) to the controller (9) through the trunk line (5) and to said computer (11) through the network cable (10) in the manner discussed below.

In accordance with present embodiment, said interface circuit board (3) is configured to transmit data to the computer (11) by using communication protocol data unit (12) (Fig. 2) that is capable of sending and receiving data to and from said PLC and the computer. It is to be noted that components of said communication protocol data unit (12) are determined, altered, and adjusted according to modes of communications operation and types of communication protocols to be used.

Now, said interface circuit board (3) according to Fig. 2 is, for example, a thick film substrate carries a plurality of surface-mounted components (not shown) thereon. It includes a copper-lined throughgoing contact holes assembly (H) having a plurality of contact holes (H1 to Hn), a terminal assembly (T) having plurality of terminals (T1 to Tn), a communication protocol data unit (12) having a central controller (12a) and a network port (12c). It is to be noted that the term “central controller” includes a configuration according to communication protocol to be used. Said central controller (12a) having a power pin (M1), a ground pin (M8) and plurality of data pin (M2 to M7). Said central controller (12a) emit and receive, respectively, output signals of said input devices by interfacing it with said computer (11) directly or through any interfacing chip by said network cable (10). One end of said network cable (10) is plugged inside the network port (12c) and other end thereof is plugged inside the USB port of the said computer (11) so that said central controller is interfaced with the computer (11) through the network cable (10). Thus, the data of output signals of each input device are communicated with the computer (11). Further, said interface circuit board (3) comprises a conductive paths (tracks) (shown in Fig. 2) plated on the upper surface thereof that initiate from contact holes assembly (H) and electrically terminate at pins (M1 to M8) of said central controller (12a) in the manner discussed below. Said contact holes (H1 to Hn) will be bonded (as by soldering) to conductive cables or distributed channels (4) as will be described later. Said terminals (T1 to Tn) of said terminal assembly (T) are electrically connected with the controller i.e. PLC (programmable logic controller) through a trunk line (5) to facilitate the rapid deployment of signals of inputs devices (sensor) with the controller i.e. PLC. Typically, said PLC comprises input modules for receiving input signals (power signals and data signals) and output module for distributing said input signal (power signals and data signals) to their corresponding outputs.

Referring continuous with Fig. 2, a ground wire (C), a power wire (B) and a signal wire (A) of each distributed channel (4) are individually connected with corresponding contact holes (H1 to Hn) of the contact hole assembly (H) by removing enough insulation from the end of the each wire to permit the each to be later soldered (or otherwise bonded) to the holes. The colour code of the wire assembly of each distributed channel (4) is kept different which are internationally standardized so that it can be easily and safely identified by user.

Now, according to configuration of conductive paths (tracks) being designed on the circuit board (3) as shown in Fig. 2, the contact holes that receive the power wires (B) from the distributed channels (4) are shorted and carried through a common power track (B’). Said common power track (B’) is terminated at the pin (M1) of said central controller wherefrom it is extended and terminated at one of the terminal of terminal assembly (T). Likewise, the contact holes that carry the ground wire (C) are shorted and carried through a common ground track (C’). Said common ground track (C’) is terminated at the pin (M8) wherefrom it is extended and terminated at one of the terminal of the terminal assembly (T). Said common power track (B’) and the common ground track (C’) provide regulated power supply for operating said central controller (12a). Thus, by combining the power wires (B) and the ground wires (C) of each distributed channel (4), only two terminals are required to carry power signals coming from said input devices. Further, the power signal of each input device is indicated by said LEDs. The surface mounted components (not shown) control and limit the voltage given to the LEDs and to the central controller (12a) so that enough supply is provided to the LED and the central controller.

Further, the contact holes that receive signal wire (A) are respectively connected to the data pins (M2 to M7) of said central controller (12a) through a respective signal carrying track (A’). Said central controller (12a) reads output signals coming through said signal carrying tracks (A’) and transmits the data of output signals to the computer (11) through the network cable (10) so that the status of output signal of each sensing device (input device) are graphically represented on screen of said computer (11). Hence, rather conventionally, in system according to present invention, said network cables are not required to connect with PLC due to which required length of network cable can be kept to short.

Said signal carrying tracks (A’) are electrically communicated with the LEDs (6) (shown in Fig. 1) such that the LEDs will illuminate when the output signal is generated by its corresponding sensor. Thus, the status of output signal of each input is easily visualized by the operator. Hence, if any fault occurs during transmission of power signals and output signals from input device (sensor), corresponding LED will turn off and accordingly the status of power signal and output signal will be visualized on computer through said software so that operator can easily find the fault without tempering other connections. Hence, due to the system according to present invention, a tremendous saving in labour and cost is achieved because only a fraction of number of connection needs to be made and only a friction of wire needs to be run. Thus, the cumbersomeness of checking individual wire during troubleshooting to find faulty connection is substantially reduced.

Further, said output signals from the communication protocol data unit (12) are carried towards terminal (T1 to Tn) of terminal assembly (T) through respective data lines (R1 to Rn) wherefrom said signals are carried to the PLC through the terminal wire (W1 to Wn) of said trunk line (5) respectively.

Referring continues to Fig. 2, one end of said multicore trunk line (5) is connected with input module of PLC (9) by industrial standard connector (8). It is to be noted that said industrial standard connector (8) is changed according to the types of communication protocol to be used. Said trunk line (5) carries a multiple signals simultaneously through a single cable through which wiring to be done at PLC and labour cost of installation, maintenance and troubleshooting is substantially reduced. Another end of said trunk line (5) is connected with said terminal assembly (T) so that multiple input devices can share even one connection with said PLC (9). Hence, only a single communication cable has to be run for carrying multiple I/O signals. Thus, signals from input devices (sensors) are easily supplied to the PLC (9) by single cable (trunk line) (5).

Now, said system is configured to distribute the output signals through the PLC to output devices. Generally, PLC is programmed to distribute the signals of corresponding input to their corresponding output. Here, the system described in first embodiment will work reversely. According to this embodiment, the trunk line (5) is connected with the output modules of PLC through industrial standard connector (8) as describe above. Also the hub (2), the trunk line (5) and the conductive cable or distributed channels (4) are connected in the manner as described in previous embodiment. Here, the output devices (i.e. actuators) will be connected to the distributed channels (4) through industrial standard connector (8). Further, the configuration of trunk line (5), hub (2), communication interface circuit board (3) and distributed channels (4) are same as described in first embodiment. Thus, the signals from inputs devices are delivered to their corresponding output devices by reducing cable harnessing on substantial extent.

It is appreciated that said communication protocol data unit (12) is configured to support various process automation network protocols. The list of said protocols is given below Table for reference.

Application Protocols Description
Process Automation
protocols AS-i
Actuator-sensor interface, a low level 2-wire bus establishing power and communications to basic digital and analog devices
BSAP
Bristol Standard Asynchronous Protocol, developed by Bristol Babcock Inc.
CC CC-Link Industrial Networks – Supported by the CLPA
CIP
(Common Industrial Protocol) – can be treated as application layer common to DeviceNet, CompoNet, ControlNet and EtherNet/IP

CAN Controller Area Network utilized in many network implementations, including CANopen and DeviceNet

ControlNet
An implementation of CIP, originally by Allen-Bradley

DeviceNet
An implementation of CIP, originally by Allen-Bradley

DF-1
Used by Allen-Bradley PLC-5, SLC-500, and MicroLogix class devices
DirectNet
Koyo / Automation Direct proprietary, yet documented PLC interface
EtherCAT

EGD Ethernet Global Data (EGD) – GE Fanuc PLCs (see also SRTP)

EtherNet/IP
IP stands for "Industrial Protocol". An implementation of CIP, originally created by Rockwell Automation

Ethernet Powerlink
An open protocol managed by the Ethernet POWERLINK Standardization Group (EPSG)
FINS
Omron's protocol for communication over several networks, including Ethernet.
fieldbus H1 & HSE

HART
HostLink Omron's protocol for communication over serial links.
Interbus
Phoenix Contact's protocol for communication over serial links, now part of PROFINET IO
MACRO Fieldbus
"Motion and Control Ring Optical" developed by Delta Tau Data Systems.
MECHATROLINK
Open protocol originally developed by Yaskawa, supported by the MMA

MelsecNet
Supported by Mitsubishi Electric

Modbus Modbus PEMEX

Modbus Plus

Modbus RTU or ASCII or TCP
OSGP
The Open Smart Grid Protocol, a widely use protocol for smart grid devices built on ISO/IEC 14908.1
Optomux
Serial (RS-422/485) network protocol originally developed by Opto 22 in 1982. The protocol was openly documented and over time used for industrial automation applications.
PieP
An Open Fieldbus Protocol
Profibus
By PROFIBUS International
PROFINET IO

RAPIEnet
Real-time Automation Protocols for Industrial Ethernet
Honeywell SDS
Smart Distributed System – Originally developed by Honeywell. Currently supported by Holjeron.

SERCOS III
Ethernet-based version of SERCOS real-time interface standard
SERCOS SERCOS interface, Open Protocol for hard real-time control of motion and I/O

SSCNET
Servo System Controller Network by Mitsubishi Electric for control of motion and I/O
GE SRTP
GE Fanuc PLCs

Sinec H1
Siemens

SynqNet
Danaher

TTEthernet
TTTech

ZigBee
Open protocol

The system according to present invention is configured to perform serial data communication by using different industrial standard communication protocol. The components and operation of the system according to present invention by using mostly used communication protocols is illustrated more in details in the following example. The example describes and demonstrates embodiments within the scope of the present invention. This example is given solely for the purpose of illustration and is not to be construed as limitations of the present invention, as many variations thereof are possible without departing from spirit and scope.

Example 1:

There is illustrated in Fig. 3 a first embodiment of the system according present invention that has been simplified by presenting its most basic components. The present invention according to Fig. 3 is directed for facilitating communication between input devices and the computer by using a modbus network protocol.

Now as shown in Fig. 3, the system according to present invention was comprised of a hub (2), plurality of distributed channel (4), a controller (9), a trunk line (5) having plurality of terminal wires (W1, W2, W3, W4) for transmitting plurality of signals simultaneously to the controller (PLC) (9), a network cable (10) and a personal digital computer (11) having a software of supervisory Control and Data Acquisition (SCADA) application for graphic representation of status of signals associated with the automation system and to control some aspects of system operation by gathering the data from said hub (2) in real time from remote location.

Said hub (2) included a communications interface circuit board (3) being disposed within its interior space (shown in Fig. 2), a plurality of aperture (not shown) linearly disposed on its front wall (F), each said aperture receives at least one conductive cable or distributed channel (4) such that each distributed channel is electrically connected to said interface circuit board (3), a hole made on rear side (R) thereof wherefrom the trunk line (5) is connected and extended to be connected with said PLC (controller) through industrial standard connector (8), pluralities of LEDs (6) linearly arranged on and protruded from the annular cavities (not shown) opening on the upper wall (U) of the hub (2), a couple of screw-mounting holes (7) made on its upper surface (U) and lower surfaces (not shown) wherein a suitable screw is inserted and extended through the interface circuit board (3) for firmly fixing said circuit board (3) in the hub (2).

Said interface circuit board (3) according to Fig. 3 was comprised of a copper-lined throughgoing contact holes assembly (H) having plurality of contact holes (H1 to H18), a terminal assembly (T) having plurality of terminals (T1 to T4), a communication protocol data unit (12) having a central controller (12a) (micro controller), a RS-485 interface IC having transmit data (TX) pin (X1) and receive data pin (RX) pin (X2) to communicate with said micro controller (12a) and a network port (12c). Said micro controller (12a) having a power pin (M1), a ground pin (M8) and plurality of data pin (M2 to M7). Said TX pin (X1) and RX pin (X2) emited and received, respectively, output signals of said input devices by interfacing said RS485 IC with the microcontroller (12a). Further said RS 485 interface IC (12b) was interfaced with the computer (11) through the RS 485 to USB converter network cable (10). Thus, the data of output signals of each input device was communicated with the computer (11).

Now referring continuous with Fig. 3, the ground wire (C) of each distributed channel (4) was connected to the contact holes (H3, H6, H9, H12, H15 and H18) by removing enough insulation from the end of the each wire to permit the each to be later soldered (or otherwise bonded) to the holes. Like wise, the power wire (B) of each distributed channel (4) was electrically connected with the contact holes (H2, H5, H8, H11, H14 and H17). Further, the signal wire (A) of each distributed channels (4) was connected with the contact holes H1, H4, H7, H10, H13 and H16 in aforesaid manner.

The signals coming from power wires (B) received through contact holes (H2, H5, H8, H11, H14 and H17) was carried through the common power track (B’) by shorting said contact holes (H2, H5, H8, H11, H14 and H17) and terminated at the pin (M1) of said central controller (12a) wherefrom it was extended and terminated at terminal (T1) of said terminal assembly (T). Likewise, the signals coming from the ground wires (C) received through the contact holes (H3, H6, H9, H12, H15 and H18) was carried through the common power track (C’) by shorting said contact holes (H3, H6, H9, H12, H15 and H18) and terminated at the pin (M8) of said central controller (12a) wherefrom it was extended and terminated at terminal (T2) of said terminal assembly (T). Said common power track (B’) and the common ground track (C’) provided regulated power supply for operating said micro controller (12a). Thus, by combining the power wires (B) and the ground wires (C) of each distributed channel (4), only two terminals (T1) and (T2) were required to carry power signals coming from said six sensors as shown in Fig. 3.

The output signals and the power signals of each input device were indicated by said LEDs. Thus, conventionally, total 12 wires that were required to connect with PLC to carry the power signals of six sensors were reduced to 2 wires according to this invention that results in substantial reduction in cable harnessing.

Further, the contact holes (H1, H4, H7, H10, H13 and H16) that received signal wire (A) were respectively connected to the pins (M2 to M7) of said micro controller (12a) through a respective signal carrying track (A’). Said central controller (12a) read output signals received through said signal carrying tracks (A’) and transmitted the data of output signals to the computer (11) through the network cable (10) so that the status of output signal of each sensing device (input device) were graphically represented on screen of said computer (11).

Said signal carrying tracks (A’) were electrically communicated with the LEDs (6) such that the LEDs were illuminated when the output signal was generated by its corresponding sensor.

Further, said output signals from said RS 485 interface IC (12b) were carried toward the terminals T3 and T4 through a data line (R1) and (R2) respectively. Said trunk line (5) carried wires (W1, W2, W3, W4) that were respectively connected to the terminals (T1, T2, T3, T4) for simultaneously communicating power signals and the output signals to the PLC. Thus, multiple I/O signals were carried and distributed to and from the PLC through a single cable and were communicated with the computer by using modbus automation protocol.

Example 2:

Now according to another embodiment of said system (1) shown in Fig. 4, said system (1) was configured to perform serial data communication with the computer (11) by using profibus (process field bus) communication protocol. In this embodiment, configuration of all components of said system was remained same as that of in Example-1. Here, the Profibus controller was utilized as a central controller (12a) in communication protocol data unit (12) that enabled the digital data communication of said output signals to the PLC through the trunk line (5) and computer. The power signals and output signals were carried towards terminals (T1 to T5) wherefrom they were carried to the PLC through the terminal wire (W1 to W5) of said trunk line (5). Here, the industrial standard connector for connecting said trunk line (5) to PLC was changed with the connector that was configured to communicate said profibus controller to the PLC.

Example 3:

According to another exemplary embodiment of the system according to present invention shown in Fig. 5, said system was configured to perform serial data communication of output signals of said input devices by using a Zigbee wireless network in harsh radio environment and in isolated location. The configuration of said system in this case was remained same as shown in Example-1. According to this embodiment, said communication protocol unit (12) was comprised of a wireless Zigbee controller (central controller) (12a) integrating Zigbee module inside it that received data from PLC and transmitted said data to the computer (11) through an antenna (13) so that real time monitoring of I/O signals was implemented. In system according to said embodiment, only a power signal is carried through the wire (W1, W2) of the trunk line (5) to the PLC (9). No physical connections were required to transmit output signals to the PLC (9) and the computer (11).
Though aforesaid network protocols are known in the art, they are not describing in detail here.

The invention has been explained in relation to specific embodiment. It is inferred that the foregoing description is only illustrative of the present invention and it is not intended that the invention be limited or restrictive thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. All substitution, alterations and modification of the present invention which come within the scope of the following claims are to which the present invention is readily susceptible without departing from the spirit of the invention. The scope of the invention should therefore be determined not with reference to the above description but should be determined with reference to appended claims along with full scope of equivalents to which such claims are entitled.