Industrial field controlling device with controller and expansion modules

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.