Disclosed is an industrial control device including a point-to-point backplane/point module architecture providing RIUP (Removal and Insertion Under Power) functionality where data communications between modules is maintained after the removal of a point module from the backplane. According to an exemplary embodiment, a backplane includes a plurality of bypass switches controlled by respective point modules, whereby data communicated bypass a removed point module interface and point-to-point data communications are provided to an inserted point module after an initial routine is executed by a microcontroller associated with the inserted point module.

An industrial system for controlling backplane communication including a cluster manager linked to Input/Output modules via a multipoint low voltage differential signaling, MLVDS, bus through passive base plates. The MLVDS bus contains a transmission line and a reception line for the cluster manager. The transmission line of the MLVDS bus is shared by the Input/Output modules for receiving data transmitted by the cluster manager. The reception line of the MLVDS bus is shared by the Input/Output modules for transmitting data to the cluster manager. The Input/Output modules are synchronized in time with the cluster manager and configured to send data on the reception line of the MLVDS bus at respective scheduled time windows.

An industrial controller with a modular backplane includes multiple modules, where each module includes a base and a chassis. Electrical connectors located on each side of the base engage the base of an adjacent module such that the bases are electrically connected. The backplane is defined by and extends through each of the bases connected to each other. A chassis is inserted into each base. Each chassis includes an embedded switch and a local circuit. The embedded switch is in communication with the base, and the local circuit performs the operation of the corresponding module. The embedded switch receives data transmitted along the backplane between bases. The embedded switch reads the data intended for the module and passes the data to the local circuit for further processing. Similarly, the embedded switch receives data from the local circuit and inserts the data on the backplane for transmission to the appropriate module.

A method and system for assigning slot addresses to modules in a fault tolerant industrial control system includes a pair of backplane switches on each base. Each backplane switch is configured to communicate between one backplane and the modules located on the base and to communicate between backplane switches located at adjacent bases. A backplane switch on a bank master base first assigns a base address and slot addresses to itself. The backplane switches on each additional base initiate transmission of a base address request. A base address response, including a base address and slot numbers for the adjacent base, is transmitted after a base has its own address assigned. Each base repeats the process in sequence along the bank, incrementing the base address by one and the slot address by the number of slots on the base and passing the new base and slot addresses along the bank.

A method and system for assigning slot addresses to modules in a fault tolerant industrial control system includes a pair of backplane switches on each base. Each backplane switch is configured to communicate between one backplane and the modules located on the base and to communicate between backplane switches located at adjacent bases. A backplane switch on a bank master base first assigns a base address and slot addresses to itself. The backplane switches on each additional base initiate transmission of a base address request. A base address response, including a base address and slot numbers for the adjacent base, is transmitted after a base has its own address assigned. Each base repeats the process in sequence along the bank, incrementing the base address by one and the slot address by the number of slots on the base and passing the new base and slot addresses along the bank.

An industrial controller with a modular backplane includes multiple modules, where each module includes a base and a chassis. Electrical connectors located on each side of the base engage the base of an adjacent module such that the bases are electrically connected. The backplane is defined by and extends through each of the bases connected to each other. A chassis is inserted into each base. Each chassis includes an embedded switch and a local circuit. The embedded switch is in communication with the base, and the local circuit performs the operation of the corresponding module. The embedded switch receives data transmitted along the backplane between bases. The embedded switch reads the data intended for the module and passes the data to the local circuit for further processing. Similarly, the embedded switch receives data from the local circuit and inserts the data on the backplane for transmission to the appropriate module.

An industrial controller with a modular backplane includes multiple modules, where each module includes a base and a chassis. Electrical connectors located on each side of the base engage the base of an adjacent module such that the bases are electrically connected. The backplane is defined by and extends through each of the bases connected to each other. A chassis is inserted into each base. Each chassis includes an embedded switch and a local circuit. The embedded switch is in communication with the base, and the local circuit performs the operation of the corresponding module. The embedded switch receives data transmitted along the backplane between bases. The embedded switch reads the data intended for the module and passes the data to the local circuit for further processing. Similarly, the embedded switch receives data from the local circuit and inserts the data on the backplane for transmission to the appropriate module.

Described herein are various technologies for monitoring the backplane of a control system and detecting modifications of the control system (e.g., removal of modules, firmware updates, etc.). A monitoring device includes a field programmable gate array (FPGA), and is connected to the backplane of the control system. The monitoring device receives signals, by way of the backplane, that are communicated among modules connected to the backplane. The monitoring device detects a modification to the control system based upon the received signals.

A modular industrial automation appliance having a backplane bus system, a plurality of functional modules connected to the backplane bus system that each include a communication network adapter, a functional unit for implementing a communication protocol stack and a bridge element linked to the communication network adapter, wherein a router module connected to the backplane bus system is provided that includes a communication network adapter, a functional unit for implementing a router communication protocol stack, where the functional unit is linked to the communication network adapter, and for each functional module a respective link element, and where in such a link element links the functional unit for implementing the router communication protocol stack to the bridge element of the respective functional module via the backplane bus system such that only the communication protocol stack of the router module includes routing functions.

The present disclosure provides a serial backplane based PLC system with a hot swap function in which when an extended module fails during communication between the backplane master unit and the backplane slave unit, communication between the backplane master unit and the backplane slave unit via the backplane bus is maintained using a backplane design technique. The system includes a central processor unit (CPU) module for transmitting an operation command; at least one extended module for receiving and processing the operation command; a backplane bus connected to a bus line for communication between the CPU module and the extended modules; and at least one backplane module connected to the backplane bus, wherein the at least one backplane module is physically detachably coupled to the at least one extended module, respectively.