Claims:We Claim,

1. A system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing that comprises a hub (2), plurality of distributed channels (4) each is configured to connect with sensors at one end thereof that generates a power signal and output signal and a trunk line (5) that is configured to connect with input and output modules of the controller at one end thereof;

wherein said hub (2) comprises a circuit board (3), a plurality of aperture each receives at least one distributed channel (4) and a plurality of LEDs (6) that are electrically communicated with the circuit board (3);

wherein each distributed channel (4) comprises a wire assembly having a signal wire (A) to the carry the output signal, a power wire (B) and a ground wire (C) to carry the power signal;

wherein said circuit board (3) comprises a plurality of contact hole (H1…..H18) and a plurality of terminals (T1….T8); a common power track (B’) and a common ground track (C’) to carry power signals and a plurality of signal carrying track (A’) each carrying at least one output signal;

wherein each contact hole (H1, H4, H7, H10, H13 and H16) is electrically connected with at least one signal wire (A), each contact hole (H2, H5, H8, H11, H14 and H17) is connected with at least on power wire (B) and each contact hole (H3, H6, H9, H12, H15 and H18) is electrically connected with at least one ground wire (C);

wherein one end of said common power track (B’) is electrically connected to the contact holes (H2, H5, H8, H11, H14 and H17) and other end is electrically connected to the terminal (T2), one end of said common ground track (C’) is electrically connected to the contact holes (H3, H6, H9, H12, H15 and H18) and other end is electrically connected to the terminal (T8), one end of each signal carrying track (A’) is electrically connected with (H1, H4, H7, H10, H13 and H16) and other end is electrically connected with to the terminals (T1, T3, T4, T5, T6, T7) respectively;

wherein said trunk line (5) comprises a plurality of terminal wires (W1…W8) that are respectively connected with the terminals (T1….T8) to supply the power signal and the output signal to and from the controller;

2. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein said sensors are connected with the distributed channels (4) using industrial standard connectors.

3. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein said trunk line (5) is connected with the controller through industrial standard connectors.

4. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein at least one LED is connected between said common power tracks (B’) signal and the common ground tracks (C’) to indicate the power signal.

5. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein each said signal carrying track (A’) is electrically communicated with LED for indicating the output signal of each sensor.

6. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein said system (1) distribute the signals to corresponding output devices (actuators) by connecting the output devices with the distributed channels (4).

7. The system for carrying and distributing multiple I/O signals though the Controller by reducing cable harnessing, wherein said system (1) is configured to connect with PLC, SCADA or other suitable controllers.

Dated this on August 20, 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: SYSTEM FOR CARRYING AND DISTRIBUTING MULTIPLE I/O SIGNALS THROUGH CONTROLLER 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.

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 and more particularly it relates to a system for carrying multiple I/O signals though the controller by reducing cable harnessing.

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.
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 system for carrying and distributing multiple I/O signals though the controller 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 system for carrying and distributing multiple I/O signals though the controller by reducing cable harnessing flexible and saves installation time and reduces potential wiring error.
Further object of present invention is to provide a system for carrying and distributing multiple I/O signals though the controller 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 system for carrying and distributing multiple I/O signals though the controller 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 system for carrying and distributing multiple I/O signals though the controller 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 system for carrying and distributing multiple I/O signals though the controller 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 system for carrying and distributing multiple I/O signals though the controller 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 carrying and distributing multiple I/O signals through the controller for reducing cable harnessing. Said system comprises a hub in which circuit board is disposed. Said circuit board comprises a plurality of contact holes whereby wire assembly of conductive cables or distributed channels is electrically connected for carrying signal from input devices (sensor) and distributing signals to the corresponding output devices (actuator) through the controller. Said circuit board is configured to reduce the number of wires that carry the power signal of multiple I/O devices. The trunk line is adapted that is connected with I/O modules of controller to carry the multiple signals of I/O devices without performing individual wiring with controller.
Detailed 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.
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 may be configured to connect with other suitable controllers.

Referring now to Fig.1 and Fig. 2, said system (1) in accordance with present invention comprises hub (2). Said hub (2) comprises a circuit board (3) and configured to meets the IP67 standard so that it protects the said circuit board (3) against dust ingress as well as immersion of water so as to can be located in a rugged industrial atmosphere. Said circuit board (3) which may be, for example, a thick film substrate carries a plurality of surface-mounted components (not shown) thereon. Conductive paths (tracks) (shown in Fig. 2) plated on the upper surface of the board (3) that initiate from copper-lined throughgoing contact holes assembly (H) having plurality of contact holes (H1……H18) and electrically terminate at terminal assembly (T) having a plurality of terminals (T1…..T8). The holes assembly (H) will be bonded (as by soldering) to conductive cables or distributed channels (4) as will be described later. Said terminals (T1…T8) 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 and output module for distributing said input signal to their outputs.

Now as shown in Fig. 1, said hub (2) includes a plurality of aperture (not shown) on its front wall (F) being adapted to receive at least one conductive cable or distributed channels (4) from each said aperture. Pluralities of LEDs (6) are linearly arranged on and are extended from the annular cavities (not shown) opening on the upper wall (U) of the hub (2). Said hub (2) also includes a couple of screw-mounting holes (7) on its upper and lower surfaces wherein a suitable screw is inserted that is extended through the circuit board (3) for firmly fixing said circuit board (3) in the hub (2). 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 contact hole assembly (H) in the manner as discussed below.

The ground wire (C) of each distributed channel (4) is 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) is electrically connected with the contact holes H2, H5, H8, H11, H14 and H17. Further, the signal wire (A) of each distributed channels (4) is connected with the contact holes H1, H4, H7, H10, H13 and H16 in aforesaid manner. 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.

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 circuit board (3) through the wire assembly. Each sensor is connected between the power wire (B) and the ground wire (C) and the data output of the sensor 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) may be configured to receive any number of inputs devices as per requirement.

In said embodiment 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 may be 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.

Fig. 2 shows a configuration of conductive paths (tracks) being designed on the circuit board (3) that is the most crucial part of this invention. Now as shown in Fig. 2, the contact holes (H2, H5, H8, H11, H14 and H17) that receive the power wires (B) from the distributed channels (4) are shorted and carried through a common power track (B’). Likewise, the contact holes (H3, H6, H9, H12, H15 and H18) that carry the ground wire (C) are shorted and carried through a common ground track (C’). Thus, only two conductive paths (B’) and (C’) are required to carry the power signal of each sensor. Said conductive paths (B’) and (C’) are terminated at the terminals (T2) and (T8) of the terminal assembly (T) respectively. Further, between the power track (B’) and the ground track (C’), an LED is mounted that continuously indicate the status of power signal generated by the sensors. The surface mounted components (not shown) control and limit the voltage given to the LED so that enough supply is provided to the LED. Thus, conventionally, total 12 wires that are required to connect with PLC to carry the power signals of six sensors are 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 receive signal wire (A) are respectively connected to the terminals (T1 and T3….T7) of said terminal assembly (T) though a signal carrying track (A’). Thus, by grouping the power wires (B) and the ground wires (C) of each distributed channel (4), only eight terminals (T1….T8) are required to carry power signal and the output signal coming from said six sensors as shown in Fig. 2.

Said signal carrying tracks (A’) are electrically communicated with the LEDs (6) 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 operator can easily find the fault without tempering other connections. Thus, the cumbersomeness of checking individual wire during troubleshooting to find faulty connection and labour intensity is substantially reduced.

Referring continues to Fig. 2, said multicore trunk line (5) is configured to connect the PLC by industrial standard connector i.e. M12/M8 (8) so that it is easily connected with input module of the PLC that avoids performing to do individual wiring with the PLC so that installation time and labour consumption is substantially reduced. Said terminals (T1…T8) are connected to the trunk line (5) that includes a plurality of terminal wires (W1….W8). One end of said trunk line (5) is connected with terminal assembly (T) by soldering each terminal wire with its corresponding terminals as shown in Fig. 2. An industrial standard connector that is to be removably attached with input module of the PLC is secured with the other end of the trunk line (5). Thus, signals from input devices (sensors) are easily supplied to the PLC by the single cable (trunk line).

According to another embodiment of present invention, said system is configured to distribute the output signals through the PLC. Generally, Said 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), circuit board (3) and distributed channels (4) will be the 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.

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.