Programmable logic controller module assembly and locking system

A system for interlocking modules of a programmable logic controllers, comprising a plurality of modules for use in a PLC system in which each module includes:

• a first interconnection feature and a second interconnection feature, the first interconnection feature of each module being configured for interconnection with the second interconnection feature of a first adjacent module;
• a connector plug portion to provide an electrical interconnection with the first adjacent module;
• and
• a corresponding plug portion configured to receive a connector plus portion of a second adjacent module, wherein at least one of the connector plug portion and corresponding plug portion is mounted for reciprocal movement into and out of the electrical connection, while the first and second adjacent modules are interconnected therewith, wherein the connector plug portion is mounted on a pivotable lever.

A PLC module configured for mounting along a common mounting structure, comprising:

• an outer housing having a back portion, a front portion, a left side and a right side;
• an attachment mechanism configured to mount the outer housing to the common mounting structure, such that the back portion lies adjacent the common mounting structure;
• a plurality of interconnection features arranged to permit sliding engagement with a pair of adjacent PLC modules connected to the common mounting structure and disposed adjacent the left side and the right side, wherein the plurality of interconnection features are oriented to permit selective insertion and removal of the PLC module while the pair of adjacent PLC modules remain in position along the common mounting structure;
• and
• an electrical connector that is selectively engageable with at least one of the pair of adjacent PLC modules subsequent to the sliding engagement with the at least one of the pair of adjacent PLC modules.

A PLC module configured for mounting along a common mounting structure, comprising:

• an outer housing having a back portion, a front portion, a left side and a right side;
• an attachment mechanism configured to mount the outer housing to the common mounting structure, such that the back portion lies adjacent the common mounting structure;
• a plurality of interconnection features arranged to permit sliding engagement with a pair of adjacent PLC modules connected to the common mounting structure and disposed adjacent the left side and the right side, wherein the plurality of interconnection features are oriented to permit removal of the PLC module while the pair of adjacent PLC modules remain in position along the common mounting structure;
• a plug connector and a plug receptacle to permit communication of signals to adjacent PLC modules, wherein the plug connector is movable with respect to the housing;
• and
• a printed circuit board mounted to the outer housing, wherein the plug connector is connected to the printed circuit board by a ribbon cable.

A PLC module configured for mounting along a common mounting structure, comprising:

• an outer housing having a back portion, a front portion, a left side and a right side;
• an attachment mechanism configured to mount the outer housing to the common mounting structure, such that the back portion lies adjacent the common mounting structure;
• a plurality of interconnection features arranged to permit sliding engagement with a pair of adjacent PLC modules connected to the common mounting structure and disposed adjacent the left side and the right side, wherein the plurality of interconnection features are oriented to permit removal of the PLC module while the pair of adjacent PLC modules remain in position along the common mounting structure;
• and
• a plug connector and a plug receptacle to permit communication of signals to adjacent PLC modules, wherein the plug connector is movable with respect to the housing, further wherein the plug connector is mounted to a pivotable lever.

A method for interlocking a plurality of modules in a PLC system, comprising:

• mechanically interlocking a first module with a second module;
• independently forming an electrical interconnection between the first module and the second module;
• mechanically interlocking a third module with the second module on an opposite side of the second module from the first module;
• mounting the first, second and third modules along a common mounting structure;
• independently forming an electrical interconnection between the second module and the third module;
• releasing the second module from the first and third modules;
• and
• removing the second module without moving the first and third modules with respect to the common mounting structure.