JP7596763B2 - Programmable controller conversion adapter and programmable controller replacement method - Google Patents

Description

The present invention relates to a conversion adapter for a programmable controller and a method for replacing a programmable controller using the conversion adapter.

Traditionally, programmable controllers that execute control processing based on equipment control programs, such as sequence programs created by users, have been widely used as control devices for controlling production equipment, such as machine tools. Programmable controllers output signals that operate output devices, such as actuators, that are installed in the movable parts of the equipment, based on the on/off states of input devices, such as various sensors, that are attached to the equipment to be controlled.

If such a programmable controller fails and requires a long time to restore, it can cause major disruption to production activities, etc., so various techniques have been proposed, such as a technology that predicts the lifespan based on the number of times a relay operates (see Patent Document 1) and a technology that quickly identifies the location of a failure when one occurs (see Patent Document 2).

Japanese Patent Application Publication No. 5-266290 Japanese Patent Application Publication No. 9-50305

When a programmable controller breaks down, it is necessary to replace the broken programmable controller immediately. Also, if a breakdown is predicted based on the period of use, etc., it is effective from the perspective of preventive maintenance to replace the programmable controller with a new one even if no breakdown has occurred.

However, while production equipment can be in operation for 10 years or more, electronic components such as CPUs (central processing units) used in programmable controllers are frequently upgraded or discontinued. As a result, when a programmable controller installed in production equipment breaks down, or when an attempt is made to replace the programmable controller for preventive maintenance, it may be that a new model of programmable controller has already been released and it is not possible to obtain a new one of the same type.

Furthermore, when a programmable controller is changed, the connection format of the signal lines connected to the input and output devices may change from terminal block connections using Y terminals or round terminals to other formats, such as rod terminals that allow for smaller size or connector connections. For this reason, even if there is a new programmable controller that is functionally compatible with the old programmable controller, if the signal line connection format has changed, the wiring of the old programmable controller cannot be used as is for the new programmable controller, and it takes a long time to reconnect the wiring. Furthermore, human wiring errors such as miswiring are likely to occur when reconnecting the wiring.

The present invention was made in consideration of the above circumstances, and its purpose is to provide a programmable controller conversion adapter that allows easy replacement of a programmable controller even if the signal line connection format differs between the programmable controllers before and after replacement.

In order to achieve the above object, the present invention provides a conversion adaptor for a programmable controller, which is configured by arranging a plurality of modules, including an input/output module to which a plurality of signal lines are connected, in a predetermined direction, the conversion adaptor comprising: a terminal block side connector that can be attached and detached to a terminal block to which a plurality of terminals attached to each end of the plurality of signal lines are fastened; a module side connector that can be fitted to the input/output module and be attached and detached to the input/output module ; and a frame body having a holding portion that holds the terminal block fitted to the terminal block side connector , and the plurality of connector terminals of the terminal block side connector and the plurality of connector terminals of the module side connector are electrically connected to each other. and the terminal block is fitted to the terminal block side connector in a state inclined with respect to a predetermined direction so that the plurality of signal lines extending from the terminal block are inclined with respect to the predetermined direction and move away from the programmable controller, and the inclination angle of the terminal block with respect to the predetermined direction is an angle such that, when a pair of the input/output modules are arranged adjacent to each other in the predetermined direction, the plurality of signal lines extending from the terminal block corresponding to one of the input/output modules do not interfere with the frame body that holds the terminal block corresponding to the other input/output module and the terminal block .

Furthermore, in order to achieve the above object, the present invention provides a method for replacing a programmable controller, comprising: installing, at an installation location of a first programmable controller, a plurality of first input/output modules each having a terminal block to which a plurality of signal lines are connected and a module body to which the terminal block can be detached; and replacing the first programmable controller with the second programmable controller, the method comprising the steps of: removing the terminal block from the module body; removing the first programmable controller from the installation location; installing the second programmable controller at the installation location; and attaching the terminal block to the plurality of second input/output modules via a conversion adapter, the conversion adapter being detachable from the terminal block. and a frame body having a holding portion for holding the terminal block engaged with the terminal block side connector, wherein the terminal block is engaged with the terminal block side connector in a state inclined with respect to the arrangement direction of the plurality of second input/output modules so that the plurality of signal lines extending from the terminal block are inclined with respect to the arrangement direction of the plurality of second input/output modules and away from the second programmable controller, and the inclination angle of the terminal block with respect to the arrangement direction is an angle such that, when a pair of the second input/output modules are arranged adjacent to each other in the arrangement direction, the plurality of signal lines extending from the terminal block corresponding to one of the second input/output modules do not interfere with the frame body that holds the terminal block corresponding to the other of the second input/output modules and the terminal block.

The programmable controller conversion adapter and programmable controller replacement method of the present invention make it easy to replace a programmable controller even if the signal line connection format differs between the programmable controller before and after replacement.

FIG. 2 is a front view showing a first programmable controller and a second programmable controller. 4A and 4B are cross-sectional views showing a module body and a terminal block of an input module. 1A is a perspective view showing a conversion adaptor, and FIG. 1B is a perspective view showing a frame, a connection board, and a molded body, which are main components of the conversion adaptor. 11 is a cross-sectional view showing a conversion adapter attached to correspond to an input module together with a terminal block. 11 is an explanatory diagram showing the conversion adaptors corresponding to the second input/output modules and the second programmable controller as viewed from below; FIG.

[Embodiment]
An embodiment of the present invention will be described with reference to Figures 1 to 5. Note that the embodiment described below is shown as a preferred specific example for carrying out the present invention, and while there are some parts that specifically exemplify various technical matters that are technically preferable, the technical scope of the present invention is not limited to this specific embodiment.

Figure 1 is a front view showing a first programmable controller 1 and a second programmable controller 2. The first programmable controller 1 and the second programmable controller 2 have approximately the same functions, and control equipment such as machine tools by executing an equipment control program created by a user. Here, the first programmable controller 1 is an older model, the second programmable controller 2 is a newer model, and a case will be described in which the first programmable controller 1 is replaced with the second programmable controller 2.

(Configuration of the First Programmable Controller 1)
The first programmable controller 1 has a plurality of modules _M1 , each of which is an operating unit having an individual function, and a base plate 10 on which the plurality of modules _M1 are mounted. The plurality of modules _M1 are detachable from the base plate 10, and are aligned in a line along a predetermined alignment direction _D1 shown in Fig. 1. The plurality of modules _M1 are aligned at equal intervals with an inter-module pitch indicated by _P1 in Fig. 1.

In this embodiment, the multiple modules _M1 are composed of a power supply module 11, a CPU module 12, two input modules 13, 14, and two output modules 15, 16. The module configuration can be changed as appropriate according to the specifications of the equipment to be controlled. In the following description, the two input modules 13, 14 and the two output modules 15, 16 of the first programmable controller 1 may be collectively referred to as the first input/output modules 13 to 16.

The CPU module 12, the input modules 13, 14, and the output modules 15, 16 can send and receive signals to and from each other via a bus line provided on the base plate 10. The base plate 10 is formed with a number of potbellied bolt insertion holes 102 through which a number of bolts 101 for fixing to a control panel are inserted. The base plate 10 also has an expansion connector 103 to which a cable for connecting an additional base plate can be attached when additional base plates are installed.

The first programmable controller 1 is fixed in a control panel so that the arrangement direction _D1 of the multiple modules _M1 is the horizontal direction and the up-down direction in Fig. 1 is the vertical direction. Hereinafter, the vertical direction when the first programmable controller 1 is fixed in the control panel will be referred to as the up-down direction, and the direction perpendicular to the arrangement direction _D1 and the up-down direction (the direction perpendicular to the paper surface in Fig. 1) will be referred to as the depth direction.

The power supply module 11 has a power supply terminal block 111 on the front side to which commercial power of, for example, 100V AC is supplied, and converts the AC voltage input to the power supply terminal block 111 into an operating voltage of, for example, 5V DC, and outputs it to the other modules M ₁ (the CPU module 12 and the first input/output modules 13 to 16) via a power supply line provided on the base plate 10.

The CPU module 12 has a communications connector 121 on the front for connecting a terminal device such as a laptop computer operated by a user, and stores the equipment control program sent from the terminal device in non-volatile memory. This equipment control program is specified as a programming language for equipment control in the international standard IEC61131-3, and more specifically, is a ladder diagram (LD) or sequential function chart (SFC), etc.

The first input/output modules 13 to 16 each have a module body 130, 140, 150, 160, and a terminal block 3A to 3D that can be attached to and detached from the module body 130, 140, 150, 160. Each of the first input/output modules 13 to 16 is provided with a pair of levers 131, 141, 151, 161, and the terminal blocks 3A to 3D can be attached and detached by opening and closing the levers 131, 141, 151, 161.

2(a) and (b) are cross-sectional views showing the module body 130 and terminal block 3A of the input module 13. Fig. 2(a) is a diagram showing the inside of the module body 130 in a cross section perpendicular to the arrangement direction _D1 , viewed from the CPU module 12 side, together with the terminal block 3A, and Fig. 2(b) is a diagram showing the inside of the module body 130 in a cross section perpendicular to the up-down direction, viewed from below to above, together with the terminal block 3A. The terminal blocks 3B to 3D are also configured in the same manner as the terminal block 3A.

The module body 130 has a resin housing 132 to which a lever 131 is attached so as to be able to swing, and a board 133 housed in the housing 132. The housing 132 has an opening 132a formed in a portion where the terminal block 3A is attached, and the lever 131 is disposed at both ends of the opening 132a in the vertical direction. The lever 131 can swing around a support shaft 132b fixed to the housing 132. The housing 132 is also provided with a rail 132c that supports the board 133.

The end of the substrate 133 near the opening 132a is an edge connector 134 for connection to the terminal block 3A, and this edge connector 134 is provided with a number of electrodes 134a. The substrate 133 also has a number of electronic components mounted thereon, including passive elements 135 such as resistors and capacitors, and a photocoupler 136. The electrodes 134a of the edge connector 134, the passive elements 135, and the photocoupler 136 are electrically connected to one another by a wiring pattern made of copper foil formed on the substrate 133, but this wiring pattern is not shown in FIGS. 2(a) and (b).

The terminal block 3A has a resin body 31, a plurality of washers 32 and bolts 33, a plurality of terminal seats 34, and a plurality of terminal fittings 35. The body 31 is provided with a plurality of (19 in this embodiment) connection parts 310, and each connection part 310 is partitioned by a wall part 311. Each connection part 310 is provided with one washer 32, one bolt 33, and one terminal seat 34. In this embodiment, the plurality of connection parts 310 are arranged in two rows, and the plurality of (10) connection parts 310 in one row are provided closer to the module body 130 in the depth direction than the plurality of (9) connection parts 310 in the other row. In addition, the body 31 is formed with a recess 312 into which the edge connector 134 fits, and an engagement recess 313 into which the engagement protrusion 131a of the lever 131 engages.

The bolt 33 is inserted through the washer 32 and screwed into the terminal seat 34. The terminal fitting 35 has a contact portion 351 at one end that contacts the electrode 134a of the edge connector 134, and the other end is connected to the terminal seat 34. The contact portion 351 protrudes into the recess 312 of the main body 31, and when the edge connector 134 is fitted into the recess 312, the contact portion 351 of the terminal fitting 35 comes into contact with the electrode 134a of the edge connector 134.

A number of signal lines 41 are connected to each of the terminal blocks 3A to 3D. Each signal line 41 is an insulated electric wire in which a conductive wire 411 made of twisted wire is covered with an insulator 412. At one end of the signal line 41, the insulator 412 is removed to expose the conductive wire 411, and the exposed conductive wire 411 is crimped and fixed to the connection terminal 42. The connection terminal 42 has a cylindrical crimping portion 421 that crimps and fixes the conductive wire 411, and a flat connection portion 422. The connection portion 422 is sandwiched between the washer 32 and the terminal base 34 by tightening the bolt 33 at the connection portion 310 of the terminal block 3A.

Although detailed illustration is omitted, the terminal blocks 3B to 3D of the input module 14 and the output modules 15 and 16 are configured similarly to the terminal block 3A of the input module 13, and a plurality of signal lines 41 are connected to each of these terminal blocks 3B to 3D. Of the plurality of connection parts 310 in the terminal blocks 3A and 3B of the input modules 13 and 14, the connection part 310 located at the lower end is connected to a power line (common wiring) 43 via a connection terminal 42. Also, of the plurality of connection parts 310 in the terminal blocks 3C and 3D of the output modules 15 and 16, the power line 44 of an operating power supply that outputs, for example, DC 24V is connected to the connection part 310 located at the lower end via a connection terminal 42.

The multiple signal lines 41 connected to the terminal blocks 3A and 3B of the input modules 13 and 14 are input signal lines connected to input devices such as proximity switches, push button switches, or various sensors installed in the equipment to be controlled. The multiple signal lines 41 connected to the terminal blocks 3C and 3D of the output modules 15 and 16 are output signal lines connected to output devices such as various actuators installed in the equipment to be controlled. These output devices operate using the output voltage of the operating power supply.

Information on the signal state of the signal line 41 connected to the terminal blocks 3A, 3B is transmitted to the CPU module 12 via the input modules 13, 14 and the base plate 10. In the equipment control program executed by the CPU module 12, the relationship between the on/off states of multiple input devices and the on/off states of the output devices to be operated is defined, for example, in the form of a ladder diagram. In accordance with this equipment control program, the CPU module 12 sends command signals to the output modules 15, 16 according to the on/off states of the input devices, turning on/off switching elements such as relays or transistors in the output modules 15, 16.

(Configuration of the second programmable controller 2)
Next, the second programmable controller 2 will be described. As with the first programmable controller 1, the second programmable controller 2 has a plurality of modules _M2 arranged along a predetermined arrangement direction _D2 and a base plate 20 on which the plurality of modules _M2 are mounted, and the plurality of modules M2 are composed of a power supply module 21, a CPU module ₂₂ , two input modules 23 and 24, and two output modules 25 and 26. The power supply module 21, the CPU module 22, the input modules 23 and 24, and the output modules 25 and 26 have the same functions as the power supply module 11, the CPU module 12, the input modules 13 and 14, and the output modules 15 and 16 of the first programmable controller 1, respectively.

Furthermore, the power supply module 21, CPU module 22, input modules 23, 24, and output modules 25, 26 of the second programmable controller 2 are smaller than the power supply module 11, CPU module 12, input modules 13, 14, and output modules 15, 16 of the first programmable controller 1, and the inter-module pitch _P2 of the multiple modules _M2 in the second programmable controller 2 is narrower than the inter-module pitch _P1 in the first programmable controller 1. In the following description, the two input modules 23, 24 and the two output modules 25, 26 may be collectively referred to as the second input/output modules 23 to 26.

The power supply module 21 has a power supply terminal block 211 on the front, converts the AC voltage input to the power supply terminal block 211, and outputs it as an operating voltage to the CPU module 22 and the second input/output modules 23 to 26. The CPU module 22 has a communication connector 221 on the front for connection to a user's terminal device, and stores the equipment control program sent from the terminal device in non-volatile memory and executes it.

The second input/output modules 23 to 26 each have a module body 230, 240, 250, or 260, and a terminal block 5A to 5D that is detachable from the module body 230, 240, 250, or 260. The module bodies 230, 240, 250, or 260 each have a board on which electronic components are mounted, and this board is housed in a housing 232, 242, 252, or 262.

Each of the second input/output modules 23 to 26 is provided with a pair of levers 231, 241, 251, 261 that can swing relative to the housings 232, 242, 252, 262, and the terminal blocks 5A to 5D can be attached and detached by opening and closing the levers 231, 241, 251, 261. The terminal blocks 5A to 5D are push-in type terminal blocks in which the rod-shaped terminals are fixed by inserting them into the terminal insertion holes 51, and when removing the terminals from the terminal insertion holes 51, a tool such as a flathead screwdriver is inserted into the release hole 52 provided near the terminal insertion hole 51 to release the terminals.

The base plate 20 is provided with an expansion connector 203, similar to the base plate 10 of the first programmable controller 1, and has a number of bell-shaped bolt insertion holes 202 formed in the four corners for fixing to a control panel. The arrangement and size of these bolt insertion holes 202 are the same as the arrangement and size of the bolt insertion holes 102 of the base plate 10 of the first programmable controller 1. Therefore, after loosening the multiple bolts 101 and removing the first programmable controller 1, it is possible to fix the second programmable controller 2 to the control panel by inserting these bolts 101 directly into the bolt insertion holes 202 of the base plate 20 of the second programmable controller 2 and tightening them.

The base plate 20 also has an empty slot 200 in which no module is attached. Fig. 1 illustrates a module connection connector 204, an engagement hole 205 for fixing a module, and a screw hole 206 in this empty slot 200. The module connection connector 204, the engagement hole 205 for fixing a module, and the screw hole 206 are provided corresponding to each of the multiple modules _M2 attached to the base plate 20.

The multiple modules _M2 are connected to a bus line provided on the base plate 20 via module connection connectors 204, and are capable of transmitting and receiving signals via this bus line. The second input/output modules 23 to 26 are attached to the base plate 20 by engaging the lower ends of the housings 232, 242, 252, and 262 with the engagement holes 205, and by screwing bolts inserted through the upper ends of the housings 232, 242, 252, and 262 into the screw holes 206.

Furthermore, the base plate 20 is formed with adapter fixing holes 207 for fixing a conversion adapter, which will be described later. In this embodiment, the adapter fixing holes 207 are screw holes, and are formed at positions below the module bodies 230, 240, 250, and 260 corresponding to each of the second input/output modules 23 to 26.

The second programmable controller 2 replaces the first programmable controller 1 when the first programmable controller 1 breaks down or when the first programmable controller 1 is replaced for preventive maintenance. In this embodiment, a conversion adapter is used to facilitate this replacement. Next, the conversion adapter and the method of replacing the programmable controller will be described with reference to Figures 3 to 5.

(Configuration of conversion adapter)
Fig. 3(a) is a perspective view showing the conversion adaptor 6. Fig. 3(b) is a perspective view showing the main components of the conversion adaptor 6, namely, the frame 7, the connection board 8, and the molded body 9. Fig. 4 is a cross-sectional view showing the conversion adaptor 6 attached in correspondence with the input module 23, together with the terminal block 3A. Fig. 5 is an explanatory diagram showing the four conversion adaptors 6 corresponding to the second input/output modules 23 to 26, respectively, and the second programmable controller 2, as viewed from below.

The conversion adapter 6 comprises a frame 7 formed by punching and bending a metal plate, a connection board 8 having a terminal block side connector 80 that can be attached to and detached from the terminal blocks 3A to 3D, and a molded body 9 having a module side connector 90 that can be attached to and detached from the second input/output modules 23 to 26. Any of the terminal blocks 3A to 3D can be mated with the terminal block side connector 80, and the module side connector 90 can be mated with any of the second input/output modules 23 to 26. However, FIG. 4 shows a case where the terminal block 3A is mated with the terminal block side connector 80, and the module side connector 90 is mated with the input module 23. The conversion adapter 6 shown in FIG. 4 will be described in detail below as an example.

The frame 7 integrally includes a holding portion 71 for holding the terminal block 3A fitted into the terminal block side connector 80, a housing portion 72 for housing the molded body 9, and legs 73 extending from the holding portion 71 in a direction intersecting the arrangement direction _D2 (depth direction) and fixed to the base plate 20. The housing portion 72 has a pair of walls 721, 722 facing each other along the arrangement direction _D2 , and the molded body 9 is disposed between these walls 721, 722. The housing portion 72 also has an opening 720 that opens toward the input module 23, and the module side connector 90 protrudes from this opening 720.

The frame 7 has the holder 71 disposed on the opposite side of the second input/output modules 23-26 from the base plate 20, i.e., on the front side of the second input/output modules 23-26 to which the terminal blocks 5A-5D are attached. The legs 73 extend from the lower end of the holder 71 in the vertical direction toward the base plate 20, and have bolt insertion holes 731a formed in their tips 731. The frame 7 is fixed to the base plate 20 by the bolts 62 (shown in FIG. 5) inserted into the bolt insertion holes 731a and screwing into the adapter fixing holes 207 of the base plate 20.

The connection board 8 is a solid board with a base material 81 being a flat insulating resin made of glass epoxy or the like. The terminal block side connector 80 is an edge connector provided at the end of the base material 81, and a plurality of electrodes 801 are formed on the front surface 81a and the back surface 81b of the base material 81 as connector terminals of the terminal block side connector 80. In Figs. 3 and (b), ten electrodes 801 are formed on the front surface 81a of the base material 81. Nine electrodes 801 are formed on the back surface 81b of the base material 81. When the terminal block 3A is fitted to the terminal block side connector 80, the plurality of contact portions 351 of the terminal block 3A come into contact with the plurality of electrodes 801 of the terminal block side connector 80.

The connection board 8 has a number of through holes 82 formed between the front surface 81a and the back surface 81b of the base material 81, corresponding to the electrodes 801, and lands 83 formed around each through hole 82. Each land 83 is connected to an electrode 801 by a wiring pattern 84. A pair of slits 70 are formed in the frame 7, and both ends of the connection board 8 in the longitudinal direction (the direction in which the electrodes 801 are arranged) are inserted into these slits 70.

The molded body 9 has a resin part 91 made of molded resin and a plurality of wiring members 92 made of conductive metal embedded in the resin part 91. The resin part 91 integrally has a main body part 911 accommodated in the accommodation part 72 and a connector part 912 constituting the outer shell of the module side connector 90. The main body part 911 has a flat abutment surface 911a against which the back surface 81b of the base material 81 in the connection board 8 abuts, and a pair of through holes 911b extending parallel to the arrangement direction _D2 , and the shaft-shaped member 61 (see FIG. 3A) is inserted into the through hole 911b. The shaft-shaped member 61 has both ends fitted into fitting holes 721a, 722a (see FIG. 3B) formed in a pair of wall parts 721, 722 of the frame body 7, respectively, to position and fix the molded body 9 to the frame body 7.

One end 921 of the wiring member 92 protrudes from the abutment surface 911a, and this one end 921 is inserted into the through hole 82 and soldered to the land 83. The other end of the wiring member 92 serves as a contact portion 922 serving as a connector terminal of the module side connector 90. The module side connector 90 is inserted into the housing 232 of the input module 23 through an opening 232a formed in the housing 232, and engages with an edge connector 234 provided at the end of a board 233 housed in the housing 232.

The edge connector 234 has multiple electrodes 234a and is provided near the opening 232a in the substrate 233. When the module side connector 90 is mated with the edge connector 234, the multiple contact portions 922 of the module side connector 90 come into contact with the multiple electrodes 234a of the edge connector 234. In addition, the substrate 233 is mounted with multiple electronic components such as passive elements 235, such as resistors and capacitors, and photocouplers 236.

In the state before the conversion adapter 6 is attached (the state shown in FIG. 1), the terminal block 5A is engaged with the edge connector 234, and the opening 232a is blocked by the terminal block 5A. When replacing the first programmable controller 1 with the second programmable controller 2, the lever 231 is opened to remove the terminal block 5A, making it possible to engage the module side connector 90 with the edge connector 234.

In the conversion adapter 6, one end 921 of the wiring member 92 is soldered to the land 83 of the connection board 8, so that the multiple electrodes 801 of the terminal block side connector 80 and the multiple contact portions 922 of the module side connector 90 are electrically connected to each other. As a result, the terminal block 3A fits into the terminal block side connector 80, and the module side connector 90 fits into the edge connector 234, so that the multiple contact portions 351 of the terminal block 3A and the multiple electrodes 234a of the edge connector 234 are electrically connected to each other.

4 and 5, the terminal block 3A is fitted into the terminal block side connector 80 in a state inclined with respect to the arrangement direction _D2 so that the multiple signal lines 41 extending from the terminal block 3A are inclined with respect to the arrangement direction _D2 and away from the programmable controller 2. Similarly, the terminal blocks 3B to 3D are fitted into the terminal block side connector 80 so that the multiple signal lines 41 extending from the terminal blocks 3B to 3D are inclined with respect to the arrangement direction _D2 and away from the programmable controller 2.

As shown in Fig. 4, the connection board 8 is inclined at an inclination angle θ with respect to the arrangement direction _D2 . This inclination angle θ is an angle at which a plurality of signal lines 41 extending from a terminal block (terminal block 3B) corresponding to one (e.g., input module 24) of two adjacent modules _M2 (e.g., input module 23 and input module 24) among the second input/output modules 23 to 26 do not interfere with the frame body 7 holding the terminal block (terminal block 3A) corresponding to the other (e.g., input module 23) and the terminal block (terminal block 3A), and is, for example, 30 to 50°. Figs. 4 and 5 show a case where the inclination angle θ is 40° as an example.

(How to replace a programmable controller)
When replacing the first programmable controller 1 with the second programmable controller 2, the second programmable controller 2 is installed in the installation location of the first programmable controller 1. At this time, while the multiple signal lines 41 and the power supply line (common wiring) 43 and the power supply line 44 are connected to the terminal blocks 3A to 3D of the first programmable controller 1, the terminal blocks 3A to 3D are removed from the first input/output modules 13 to 16, and the removed terminal blocks 3A to 3D are attached to the second input/output modules 23 to 26 via the conversion adapters 6, respectively.

More specifically, the first programmable controller 1 is replaced with the second programmable controller 2 through the following steps: a first step of removing the terminal blocks 3A-3D from the module bodies 130, 140, 150, 160 of the first input/output modules 13-16; a second step of removing the first programmable controller 1 from its installation location; a third step of installing the second programmable controller 2 at this installation location; and a fourth step of attaching the terminal blocks 3A-3D to the second input/output modules 23-26 via the conversion adapter 6. Note that the terminal blocks 5A-5D are assumed to be removed from the second input/output modules 23-26 in advance.

[Effects of the embodiment]
According to the present embodiment described above, the terminal blocks 3A to 3D removed from the first programmable controller 1 can be attached directly to the module bodies 230, 240, 250, 260 of the second input/output modules 23 to 26 without removing the multiple signal lines 41, etc., eliminating the need to replace the connection terminals 42, etc., and making it possible to easily replace the first programmable controller 1 with the second programmable controller 2.

Furthermore, the terminal blocks 3A to 3D are fitted into the terminal block side connector 80 of the conversion adapter 6 in a state inclined with respect to the arrangement direction _D2 so that the multiple signal lines 41 extending from the terminal blocks 3A to 3D are inclined with respect to the arrangement direction _D2 and away from the second programmable controller 2. Therefore, even though the inter-module pitch _P2 of the second programmable controller 2 is narrower than the inter-module pitch _P1 of the first programmable controller 1, it is possible to connect the terminal blocks 3A to 3D to the second input/output modules 23 to 26.

Furthermore, since the legs 73 of the frame 7 extending in a direction intersecting the arrangement direction _D2 are fixed to the base plate 20, the conversion adaptor 6 can be easily attached to the second programmable controller 2.

(Additional Note)
Although the present invention has been described above based on the embodiment, the invention according to the claims is not limited to the embodiment. It should be noted that not all of the combinations of features described in the embodiment are necessarily essential to the means for solving the problems of the invention.

The present invention can be modified as appropriate by omitting some of the configuration or adding or replacing configurations without departing from the spirit of the invention. For example, in the above embodiment, the terminal blocks 5A to 5D of the second input/output modules 23 to 26 of the second programmable controller 2 are push-in type terminal blocks in which rod-shaped terminals are inserted into the terminal insertion holes 51, but the present invention is not limited to this. For example, the input signal lines or output signal lines may be connected to connectors that are detachable from the module bodies 230, 240, 250, and 260 of the second input/output modules 23 to 26. In the second programmable controller 2, the power supply module 21 and the CPU module 22 may be integrated.

1...First programmable controller 13-16...First input/output module 130, 140, 150, 160...Module body 2...Second programmable controller 20...Base plate 23-26...Second input/output module 230, 240, 250, 260...Module body 3A-3D...Terminal block 41...Signal line 42...Connection terminal 6...Conversion adapter 7...Frame 71...Holding portion 72...Accommodation portion 73...Leg portion 80...Terminal block side connector 801...Electrode (connector terminal)
90: Module side connector 922: Contact portion (connector terminal)
P ₁ , P ₂ ... module pitch θ ... inclination angle

Claims (3)

A conversion adapter for a programmable controller, comprising a plurality of modules arranged in a predetermined direction, including an input/output module to which a plurality of signal lines are connected,
a terminal block side connector that can be detachably attached to a terminal block to which a plurality of terminals attached to ends of the respective signal lines are fastened, a module side connector that can be fitted to the input/output module and can be detachably attached to the input/output module, and a frame having a holding portion that holds the terminal block fitted to the terminal block side connector,
a plurality of connector terminals of the terminal block side connector and a plurality of connector terminals of the module side connector are electrically connected to each other;
the terminal block is fitted to the terminal block side connector in a state inclined with respect to the predetermined direction so that the signal lines extending from the terminal block are inclined with respect to the predetermined direction and separated from the programmable controller,
the inclination angle of the terminal block with respect to the predetermined direction is an angle at which, when a pair of the input/output modules are disposed adjacent to each other in the predetermined direction, the signal lines extending from the terminal block corresponding to one of the input/output modules do not interfere with the frame body holding the terminal block corresponding to the other input/output module and the terminal block.
Programmable controller conversion adapter. the programmable controller has a base plate on which the plurality of modules are mounted;
the frame has a holding portion disposed on a side opposite to the base plate with respect to the input/output module, and a leg portion extending from the holding portion in a direction intersecting the predetermined direction and fixed to the base plate,
2. A conversion adaptor for the programmable controller according to claim 1. 1. A method for replacing a programmable controller, comprising: installing a second programmable controller having a plurality of second input/output modules arranged at an inter-module pitch narrower than an inter-module pitch of the plurality of first input/output modules, the inter-module pitch being narrower than that of the plurality of first input/output modules, at an installation location of a first programmable controller, the first programmable controller being equipped with a plurality of first input/output modules each having a terminal block to which a plurality of signal lines are connected and a module main body to which the terminal block can be detached; and replacing the first programmable controller with the second programmable controller,
removing the terminal block from the module body;
removing the first programmable controller from the installation location;
installing the second programmable controller at the installation location;
and attaching the terminal block to the second input/output modules via a conversion adapter.
the conversion adaptor includes a terminal block side connector that is detachable from the terminal block, a module side connector that is fitted to the second input/output modules and is detachable from the second input/output modules , and a frame having a holding portion that holds the terminal block fitted to the terminal block side connector ;
the terminal block is fitted to the terminal block side connector in a state inclined with respect to an arrangement direction of the second input/output modules so that the signal lines extending from the terminal block are inclined with respect to the arrangement direction of the second input/output modules and are spaced away from the second programmable controller;
the inclination angle of the terminal block with respect to the arrangement direction is an angle at which, when a pair of the second input/output modules are arranged adjacent to each other in the arrangement direction, the signal lines extending from the terminal block corresponding to one of the second input/output modules do not interfere with the frame body that holds the terminal block corresponding to the other of the second input/output modules and the terminal block.
How to replace a programmable controller.

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