WO2015174971A1

WO2015174971A1 - Configurable input/output module and method therefore

Info

Publication number: WO2015174971A1
Application number: PCT/US2014/037950
Authority: WO
Inventors: Daniel Milton ALLEY
Original assignee: Ge Intelligent Platforms, Inc.
Priority date: 2014-05-14
Filing date: 2014-05-14
Publication date: 2015-11-19

Abstract

A universal Input/Output (I/O) module includes a terminal block having at least one terminal, a switching block coupled to the terminal block and having one or more channels and a plurality of switches selectively configurable according to a first set of downloadable information and adaptable for use in a plurality of systems having potentially different configurations for the switches, and a plurality of hardware resources coupled to the switching block. The downloadable information configures the switching block to establish and maintain one or more communication paths between the terminal block and the plurality of hardware resources. The universal I/O module may replace a quantity of other module products, thus reducing manufacturing and stocking costs.

Description

CONFIGURABLE INPUT/OUTPUT MODULE AND METHOD THEREFORE

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

[0001] The subject matter disclosed herein generally relates to a universal Input/Output (I/O) module for replacement of existing I/O modules within a product line.

BRIEF DESCRIPTION OF THE RELATED ART

[0002] A variety of approaches have been used in the creation of I/O architecture, including the use of numerous I/O modules to obtain the desired architecture. The configurations of these I/O modules vary greatly, for example, by the number of channels, type of sensed input or driven output, and connector style, among other characteristics.

[0003] Unfortunately, the number of I/O modules needed to monitor, support, and/or control these varying architectures is also increasing, thus resulting in larger product catalogs and increased factory costs. Further, it may be difficult to select a correct module based on individual needs due to the large number of modules to choose from.

[0004] The above-mentioned problems have resulted in some user dissatisfaction with previous approaches.

Brief Description of the Invention

[0005] The approaches described herein provide a single universal module that may replace the numerous existing modules. The universal nature of the module reduces the total product catalog size and further allows costs to be lowered through increased manufacturing efficiencies by only having to manufacture one module having a predetermined configuration. Further, due to the decreased number of replacement parts necessary to be stocked, costs incurred by users decreases.

[0006] In many of these embodiments, an I/O module comprising a terminal block, a switching block, and a plurality of hardware resources coupled to the switching block is provided. The switching block is coupled to at least one terminal of the terminal block and has one or more channels and a plurality of switches that are selectively configurable according to a first set of downloadable information. The switching block is adaptable for use in a plurality of systems having potentially different configurations for the switches. The downloadable information configures the switching block to establish and maintain one or more communication paths between the terminal block and the plurality of hardware resources.

[0007] The switching block may also be configurable according to a second set of downloadable information that is different than the first set of downloadable information and may be similarly adaptable for use in different systems having different configurations for the switches. Additionally, the switching block may be configurable according to this second set of downloadable information when another I/O module is replaced.

[0008] In some approaches, a controller may be provided that is coupled to the terminal block and be configured to send the first set of downloadable information to the switching block. The controller may also monitor the hardware resources and instruct the resources to execute a task.

[0009] Further, in other embodiments, one or more channels of the switching block include a first and second communication channel that may be associated with a first and second device type. Alternatively, the first communication channel and second communication channel may be associated with the same device type.

[0010] In another aspect, the hardware resources may be high side switches, low side signals, an analog-to-digital (A-to-D) channel, or a digital-to-analog (D-to-A) channel.

[001 1] In some aspects, a method for programming a first I/O module having a terminal block, hardware resources, and a switching block including a plurality of switches is provided. The method includes coupling a tool to the first I/O module, downloading first downloadable information from the tool to the switching block, and selectively configuring the plurality of switches according to the first downloadable information in order to establish and maintain one or more communication paths between the terminal block and the hardware resources.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawings wherein:

[0013] FIG. 1 comprises a block diagram illustrating an exemplary I/O system according to various embodiments of the present invention;

[0014] FIG. 2 comprises an operational flow chart illustrating a method for programming an

I O system according to various embodiments of the present invention;

[0015] FIG. 3 comprises a block diagram illustrating an exemplary universal I/O module according to various embodiments of the present invention;

[0016] FIGS. 4A-4E comprise a diagram illustrating a plurality of I O modules according to various embodiments of the present invention;

[0017] FIG. 5 comprises a flow chart illustrating a method for programming an I/O system according to various embodiments of the present invention.

[0018] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION OF THE INVENTION

[0019] Approaches are provided that overcome the need for large numbers of different

Input/Output (I/O) modules to build desired I/O architectures. In one aspect, universal I/O architecture using Application Specific Integrated Circuits (ASICs) allow for the direct replacement of existing I/O modules. The universal I/O module may be programmed to function similarly to the replaced modules, and include an additional parameter to specify the module being replaced.

[0020] In one specific example, a system is configured with multiple I/O modules. In this example, each I/O module has the same form factor with an eight wire terminal block for user wiring on the module front and eight contacts within flanges on each side of the module. Four of the user terminals are for signals, two are for circuit grounds, and two are for shield connections to case ground. The universal I/O module connects to the four signal wires and to the internal ground wires, thus replacing the variety of hardware circuits across the replaced modules. Contacts on the sides of the module route field power, internal power, and communications and/or reset. It is understood that in other examples, more than eight wire terminal blocks may be used, such as 16 channels on a 48 terminal block module. Advantageously, the universal I/O module conforms to the same form factor and connections previously employed to allow use within existing I/O products.

[0021] In some examples, an I/O module includes a terminal block having at least one terminal, a switching block coupled to the terminal block and having one or more channels and a plurality of switches selectively configurable according to a first set of downloadable information and adaptable for use in a plurality of systems having potentially different configurations for the switches, and a plurality of hardware resources coupled to the switching block. The downloadable information configures the switching block to establish and maintain one or more communication paths between the terminal block and the plurality of hardware resources. In some examples, the hardware resources include high side switches, low side signals, analog-to-digital channels, or digital-to-analog output channels. It is understood that any acceptable hardware resource may be incorporated into the I/O module.

[0022] In other examples, a controller may be provided that is coupled to the terminal block.

The controller is configured to send the first downloadable information to the switching block. The controller may also monitor the hardware resources and instruct the resources to execute a task.

[0023] In other aspects, the one or more channels of the switching block includes first and second communication channels. The first communication channel may be associated with a first device type, and the second communication channel may be associated with a second device type. Alternatively, the first and second communication channels may be associated with the same device type.

[0024] In some embodiments, the switching block is configurable according to a second set of downloadable information that is different from the first set of downloadable information. This second set of downloadable information is adaptable for use in a plurality of systems having potentially different configurations for the plurality of switches. The switching block may be configurable according to this second set of downloadable information when an I O module is replaced.

[0025] In some aspects, a method for programming an I/O system is described. When the

I O system is being built, individual I/O modules are connected adjacent to one another allowing for both electrical and data flow to occur. A programming tool generates a desired logic program including I/O module configuration and sends the program to a control system. The control system also receives a product catalog having I/O module configuration instructions for the I/O modules to be used.

[0026] When the I O system is initially powered, the control system determines whether the first I/O module corresponds to or matches with the information contained within the logic program. In other words, if the logic program indicates a particular type of I/O module should be located in the first I/O module slot, the control system will determine if such an I/O module is indeed located in this slot. If a match occurs, the control system continues to the next adjacent I O module to determine whether this I/O module corresponds to or matches with the information contained within the logic program for the next slot. If a match does not occur, the logic program then determines whether the I/O module located in the queried slot may be used for the purpose the logic program indicates by pulling I O module configuration instructions from the product catalog. If the I/O module can be used for the indicated purpose, the control system will provide the I O module with configuration settings for the switches to properly execute the task provided by the logic program. The method then proceeds to the next I/O module, and continues until no further I O modules are located.

[0027] Referring now to FIG. 1, one example of an I/O system 100 is described. The I/O system 100 includes a programming tool 102, a logic program 104, a product catalog including I/O module configuration instructions 106, a control system or controller 108, an I/O network 1 10, an I O block 11 1, a control side power source or supply 1 12, a field side I/O power source or supply 114, I O modules 116, 1 18, 120, 122, 124, a Network Interface and I/O power source or supply 126, a user system 128, and user wiring 130, 132, 134, 136, 138.

[0028] The programming tool 102 may be a software program that is stored in memory and executed on computing hardware. The programming tool 102 controls a portion of the operation of the I/O system 100. For example, in some approaches, the programming tool 102 may include software installed on a computing system (e.g., a laptop or desktop personal computer). In some aspects, the programming tool 102 prepares a file that contains instructions to inform the I/O modules of operating parameters.

[0029] In one aspect, the logic program 104 is a software program stored on any type of computing hardware and includes the I/O configuration file. The logic program 104 may be stored on any number of storage devices including computers, memory sticks, hard drives, and the like. In other approaches, the logic program 104 may be stored directly on a device being monitored. The logic program 104 contains the instructions received from the programming tool 102 for operating the I/O system 100, and may contain additional configuration features specific to the type of hardware system being used.

[0030] The product catalog 106 is an electronic file similarly stored on any type of computing hardware and includes I/O slice or module configuration instructions. These instructions include I/O slice or module configuration instructions or information regarding the different types of I/O modules 116, 118, 120, 122, 124 available for use in the I/O system 100. In some approaches, the product catalog 106 is a separate file from the logic program 104 as it is continuously updated with new instructions and information. Due to the number of available components, the product catalog 106 may be a large file, thus it may be beneficial to maintain it as a separate component from the logic program 104. In one example, the product catalog 106 may be updated when a new I/O module is created to include the new I/O module's configuration settings. Alternatively, the product catalog 106 may be updated when an existing I/O module receives a software upgrade. The product catalog 106 may be configured to update periodically or at a predetermined time, such as when the I/O system 100 is initiated.

[0031] The control system 108 may be any control system that controls any type of hardware or software element. For example, the control system 108 may be an industrial control system configured to monitor and control numerous sensors and measurement devices. It is understood that other examples of control systems 108 are possible.

[0032] The I/O network 110 may be any data communications network between devices. For example, the I/O network 1 10 may be an open or closed network using one or more standards such as PROFINET, PROFIBUS, or other Ethernet based standards. Other examples are possible.

[0033] The I/O block 11 1 is a modular device comprising the numerous I/O elements. The

I/O block 1 11 includes connections for the control side power source or supply 112, the field side power source or supply 1 14, the I/O modules 1 16, 118, 120, 122, and 124, and the network interface 126. In some approaches, the network interface 126 contains the same elements of the I/O modules (described in further detail elsewhere herein), with the addition of a network interface for communication with the control system 108. This network interface may communicate with the control system using any number of approaches, such as Ethernet or serial connections. It is understood that the I/O system 100 may include any number of individual I/O modules depending on desired configurations.

[0034] The user wiring 130, 132, 134, 136, and 138 may be any type of wiring or electrical devices that couple the I/O modules to the user system 128. As with the I/O modules 116, 1 18, 120, 122, and 124, any number of wires may be implemented into the I/O system 100 depending on the desired user system.

[0035] In operation, the programming tool 102 is in communication with the logic program

104, which in turn is in communication with the control system 108. Similarly, the product catalog 106 is in communication with the control system 108. The control system 108 communicates with the network interface 126 through the I/O network 1 10. The control and field side power 112, 114, respectively, provide power to the network interface 126. The network interface 126 is in communication with a first I/O module 122, which is in turn in communication with adjacent I/O module 124, continuing down the line of the remaining modules. Each I/O module is connected to the user system 128 through user wiring 130, 132, 134, 136, 138. In some approaches, the user system 128 includes high side switches, low side signals, analog-to-digital channels, and digital-to- analog output channels.

[0036] In one example of the operation of the system of FIG. 1, depending on the desired configuration of the I/O module(s) 116, 1 18, 120, 122, 124 coupled to the network interface 126, the user configures the programming tool 102 to provide the appropriate logic program 104 based on the desired system. Additionally, based on the I/O modules 1 16, 1 18, 120, 122, 124 in use, the appropriate information in the product catalog 106 is downloaded to the control system 108.

[0037] The control system 108 then sends the product catalog 106 and logic program 104 to the network interface 126, which then determines whether the I/O modules 1 16, 118, 120, 122, 124 in use may be used in accordance with the desired logic program 104. The control system 108 may also send instructions to the user system 128 for executing specified tasks. The I/O modules 116, 118, 120, 122, 124 are wired to the user system 128 according to build specifications. Because the control system 108 and network interface 126 are able to determine whether the I/O modules in use are appropriate for the desired logic program 104, the I/O system 100 is able to accurately monitor the user system 128.

[0038] In some examples, one of the universal I/O modules 116, 118, 120, 122, 124 may act as a replacement module. For example, the I/O system 100 may be using a legacy I/O module that has broken or ceased functioning as intended, or a user may simply want to replace the legacy I/O module with a universal I/O module. The I/O modules 116, 118, 120, 122, 124 may be "hot- swapped," or inserted into the I/O system 100 on-the-fly by sending the network interface 126 the logic program 104 and the I/O module configuration instructions 106 corresponding to the replacement I/O module. The I/O system 100 is then able to configure the network interface 126 to monitor or control the user system 128 in the same manner as when the legacy I/O module was employed. So configured, either a non-universal module configured to execute a specific task or a failed I/O module may be quickly replaced with minimal down time.

[0039] In other examples, the user may desire to monitor their system 128 in a second configuration. To accomplish this, a different logic program 104 is downloaded to the control system 108 and subsequently to the network interface 126. Alternatively, the user may remove any number of I/O modules 1 16, 118, 120, 122, 124 or modify the user wiring 130, 132, 134, 136, 138 to allow for different sensing or monitoring capabilities.

[0040] Referring now to FIG. 2, one example of a process 200 for programming an I/O system is described. First, at step 202, the control system powers up. Next, at step 204, the control system fetches the I/O component status.

[0041] At step 206, a determination is made as to whether the I/O component or module matches the component in the current program. Each I/O module includes a factory configured memory including an identifier and is configured to respond to an information request upon power up. When the I/O module receives this information request, it responds with the identifier. Thus, the component in the current program is compared to the received I/O module identifier.

[0042] If a match does occur, the process 200 proceeds to step 216. If the I/O component does not match, the process proceeds to step 208, where the missing I/O component is compared to database configurations for the I/O module at the same slice. These database configurations are contained in the product catalog previously described. By "slice and as used herein it is meant an individual module or component of the I/O system.

[0043] At step 210, the process 200 determines whether the I/O module is able to replace the missing I/O slice or module. In other words, the process compares the configuration of the missing I/O module to the configuration of the replacement I/O module, and determines whether the replacement I/O module may generate the same inputs and outputs as the missing I/O module. If the replacement I/O module can do this, the process proceeds to step 212, where the program configuration is altered for the replacement I/O module, and then proceeds to step 216. If it is determined that the I/O module is not able to replace the missing I/O module, the process proceeds to step 214, and is aborted due to being unable to configure the I/O module.

[0044] Upon the process 200 reaching step 216, the process proceeds download the configuration to the I/O modules through the I/O network. Subsequently, at step 218, the process performs an additional check to determine whether the I/O configuration is appropriate for proper execution of the system. If the I/O configuration is not appropriate for proper execution, the process 200 proceeds to step 214. If the I/O configuration is appropriate for proper execution, the process 200 proceeds to step 220.

[0045] At step 220, the process 200 waits for the I/O frame time to complete. Until the appropriate time has completed, the process repeats step 220. In some approaches, this frame time may be 10 milliseconds. In other approaches, more or less time is provided, including for example a fraction of a millisecond, one millisecond, or any other suitable time frame.

[0046] Upon the determination that the appropriate time has been reached, the process 200 proceeds to step 222, where inputs are read from all I/O modules. Next, at step 224, outputs are written to all I/O modules. At step 226, the process 200 executes the I/O program ladder logic. By "I/O ladder logic," it is meant instructions to perform user specified I/O operations as defined by a programming language. Examples would include logic operations and sequencing, counters, and/or other operations that execute based on the sensed inputs and/or communications from the control system in order to generate driven outputs and communications back to the control system. At step 228, the process 200 checks status for alarms and reports to the HMI. Finally, the process returns to step 220.

[0047] Referring now to FIG. 3, an illustration of an exemplary universal I/O module 300 is provided. The universal I/O module 300 includes a terminal block 302, programmable connection switch block 304, power switches 306, voltage comparators 308, a programmable gain amp (PGA) 309, four-channel analog to digital (A-D) converter (for V/mA inputs) 310, a digital to analog (D-A) converter (for V/mA outputs) 312, control and status data flow 313, control and status data flow 314, 320, status data 316, data flow 318, logic for data flow and setup 322, data flow 324, control/field galvanic isolation barrier 326, data flow 328, and an interface 330 from the network unit and control system.

[0048] In one example, the terminal block includes 8 holes or terminals for wires, for of which are user terminals which may be used to connect to the user system 128. The remaining four terminals are configured to receive electrical ground and shield connections. In many approaches, the shield connections connect to a back panel or wall of a device as opposed to electrical ground. The universal I/O module may be used with differing types of signals and flow directions to connect the user terminals in a programmable manner to a plurality of different resources previously described.

[0049] By utilizing the programmable connection switch block 304, the universal I/O module may be programmed to mimic the behavior of the I/O module being replaced upon receipt of the I/O module configuration instructions 106 of FIG. 1. The programmable connection switch block 304 allows for varying connections between the terminal block 302 to the remaining elements in FIG. 3 as necessary based on the desired logic program 104. In other words, the programmable connection switch block 304 activates or deactivates the connections between the terminal block 302 and elements such as power switches 306, voltage comparators 308, PGAs 309, and D/A for V/mA outputs 312 based on the logic program 104. In these approaches, any of these elements may be utilized or passed through.

[0050] In one example, the universal I/O module may use the power switches 306 which include switches to the power rail coming from the field power connections. Voltage comparators 308 may be employed to compare voltage measurements received at inputs. The PGA 309 may be incorporated to specify a necessary gain amplification amount to drive an A-to-D converter 310. A D-to-A converter 312 may be used to change digital signals to analog signals and to provide known currents through the terminals in order to calculate resistance.

[0051] The control and status data 320 includes data flowing directly to the switch block 304.

In some instances, when data is being used to control switch settings, it is necessary to monitor for an overcurrent situation. If this occurs, the control and status data 320 allows action similar to a circuit breaker to occur, in which the switches have breaker capability and may be shut off in the event of incorrect system wiring.

[0052] The previously-described elements pass control and status data 313, 314, 316, 318 to and from the logic for data flow and setup 322. Due to the number of signals being monitored, it may become necessary to merge and control the information with a simplified communication path. In some examples, the amount of information being transferred may be in the hundreds of bits.

Before this information is sent to the interface 330 from the network unit, a control/field galvanic isolation barrier 326 is used to isolate the data to avoid a ground loop. This barrier 326 may use a serial data flow such as a Serial Peripheral Interface (SPI). The interface 330 may send, receive, and manipulate information from the isolation barrier 326.

[0053] Referring now to FIGS. 4A, 4B, 4C, 4D and 4E together, an I/O system containing a plurality of I/O modules 400 is presented. FIG. 4A illustrates an exemplary universal I/O module 402 and universal I/O modules 412, 422, 432, 442 (FIGS. 4B-4E, respectively) illustrating different connections to provide for different inputs and outputs. The I/O modules include bus contacts 404, 414, 424, 434, 444, terminal connections or pins 406, 416, 426, 436, 446, and field power contacts 408, 418, 428, 438, 448. I/O modules 412, 422, 432, and 442 represent different configurations based on connections of the terminals or pins.

[0054] In operation, adjacent I/O modules are mated or slid into connection with one another such that the bus contacts 404, 414, 424, 434, 444 and field power contacts 408, 418, 428, 438, 448 come into contact. This contact allows for data and power flow between the adjacent I/O modules. Thus, I/O modules 402, 412, 422, 432, 442 are coupled to one another to form an I/O system in accordance with the desired inputs and outputs. Depending on desired connectivity features, the system may be modified to include varying numbers of individual universal I/O modules.

[0055] In some approaches, modifying the terminal connections 406, 416, 426, 436, 446 may create a one or multi-channel I/O module. Physically, wires connecting to the terminals are modified based on desired characteristics such as inputs or outputs. For example, the terminal connections 416 in I/O module 412 are wired to provide four channels for monitoring current or input voltage. The terminal connections 426 in I/O module 422 are wired to provide for two RTD measurements. The terminal connections 436 in I/O module 432 are wired to provide two input channels. The terminal connections 446 in I/O module 442 are wired to provide one channel for monitoring current channels. While these examples are provided, it is understood that a number of different connections may be envisioned to accommodate different uses for these I/O modules.

[0056] Referring to FIG. 5, a method 500 for programming an I/O module is provided. First, at step 502, a tool is coupled to a first I/O module. Next, at step 504, a first set of downloadable information is downloaded to a switching block. This downloadable information is adaptable for use in a plurality of systems having potentially different configurations. At step 506, switches are selectively configured according to the first set of downloadable information to establish or maintain at least one communication path between a terminal block and hardware resources.

[0057] In optional step 508, the hardware resources are monitored. Further, at optional step

510, the hardware resources are instructed to execute a task. In some approaches, configuring the plurality of switches at step 506 further includes the step of establishing a first and second communication channels and associating the first communication channel of the switching block with a first device type and associating the second communication channel of the switching block with a second device type. To accomplish this, the I/O module is wired in different configurations as described above with regards to FIGS. 4A-4E.

[0058] In still further examples, the method 500 may include the steps of determining whether the first I/O module is replacing a second I/O module. If the first I/O module is replacing the second I/O module, the method 500 further includes downloading the first module's

downloadable information using converted second module settings using at least one of the rules and data conversion tables received from a product catalog at the switching block.

[0059] In these further examples, the method 500 may include the step of replacing the second I/O module. Upon replacing the second I/O module, the switches are selectively configured according to second downloadable information different from the first downloadable information and according to a configuration of the second I/O module. Thus, in these examples, though the method 500 replaces one of the I/O modules, it still is capable of replicating the functions of the replaced I/O module. [0060] It will be appreciated by those skilled in the art that modifications to the foregoing embodiments may be made in various aspects. Other variations clearly would also work, and are within the scope and spirit of the invention. The present invention is set forth with particularity in the appended claims. It is deemed that the spirit and scope of that invention encompasses such modifications and alterations to the embodiments herein as would be apparent to one of ordinary skill in the art and familiar with the teachings of the present application.

Claims

CLAIMS What is claimed is:

1. An input/output (I/O) module comprising:

a terminal block having at least one terminal;

a switching block coupled to the terminal block, the switching block having one or more channels and a plurality of switches, the plurality of switches selectively being configurable according to first downloadable information and adaptable for use in a plurality of systems, each of the plurality of systems having a potentially different configuration for the plurality of switches; and a plurality of hardware resources coupled to the switching block;

wherein the downloadable information configures the switching block to establish and maintain one or more communication paths between the terminal block and the plurality of hardware resources.

2. The I O module of claim 1, wherein the I/O module replaces an existing I/O module by configuring the downloadable information to configure the switching block such that the one or more communication paths between the terminal block and the plurality of hardware resources are identical to one or more communication paths between a terminal block and a plurality of hardware resources in the existing I/O module.

3. The I O module of claim 1 , wherein a controller is coupled to the terminal block, wherein the controller is configured to send the first downloadable information to the switching block.

4. The I O module of claim 3, wherein the controller monitors the plurality of hardware resources and instructs the plurality of hardware resources to execute a task.

5. The I/O module of claim 1, wherein the one or more channels of the switching block comprises a first communication channel and a second communication channel.

6. The I/O module of claim 5 wherein the first communication channel is associated with a first device type and the second communication channel is associated with a second device type.

7. The I/O module of claim 5 wherein the first communication channel and the second communication channel are associated with the same device type.

8. The I/O module of claim 1, wherein the plurality of hardware resources are one or more elements selected from the group consisting of a high side switch, a low side signal, an analog-to- digital (A to D) channel, and a digital-to-analog (D to A) output channel.

9. The I/O module of claim 1, wherein the switching block is configurable according to second downloadable information that is different than the first downloadable information and is adaptable for use in a plurality of systems having potentially different configurations for the plurality of switches.

10. The I/O module of claim 9, wherein the switching block is configurable according to second downloadable information when another I/O module is replaced.

1 1. A method for programming a first input/output (I/O) module, the first I/O module including a terminal block and a switching block, the switching block including a plurality of switches, the first I/O module also including a plurality of hardware resources, the method comprising:

coupling a tool to the first I/O module;

downloading first downloadable information from the tool to the switching block;

selectively configuring the plurality of switches according to the first downloadable information to establish and maintain one or more communication paths between the terminal block and the plurality of hardware resources.

12. The method of claim 1 1, further comprising coupling an external controller to the terminal block, the external controller configured to transmit the first downloadable information to the switching block.

13. The method of claim 12, further comprising:

monitoring the plurality of hardware resources;

instructing the hardware resources to execute a task.

14. The method of claim 11, wherein selectively configuring the plurality of switches comprises: establishing a first communication channel and a second communication channel;

associating the first communication channel of the switching block with a first device type;

associating the second communication channel of the switching block with a second device type.

15. The method of claim 1 1, further comprising determining whether the first I/O module is replacing a second I/O module, and when the first I/O module is replacing the second I/O module, downloading the first module's downloadable information using converted second module settings using at least one of rules and data conversion tables received from a product catalog at the switching block.

16. The method of claim 15, further comprising replacing the second I O module, wherein upon replacing the second I/O module, the plurality of switches are selectively configured according to second downloadable information different from the first downloadable information and according to a configuration of the second I O module.