Forced output device

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By designing forced output devices of independent power modules, forced signal generation modules and switch modules in the PLC system, the problem of forced output function failure in PLC failure or power interruption is solved, and the system's continuous reliability and immediate response capabilities are achieved.

CN222979945UActive Publication Date: 2025-06-13SHANGHAI ZHENGFAN TECH +1

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Patent Information

Application Number: CN202422132246.6
Authority / Receiving Office: CN · China
Patent Type: Utility models(China)
Current Assignee / Owner
Filing Date: 2024-08-30
Publication Date: 2025-06-13
Estimated Expiration: 2034-08-30

AI Technical Summary

Technical Problem

The PLC cannot achieve the forced output function when it encounters a fault or loses the power supply, causing the production line to stagnate or cause production accidents.

Method used

A forced output device is designed, including an independent power module, a forced signal generation module and a switch module, to ensure that power is continued when the main PLC system power failure and to quickly generate and transmit forced signals.

Benefits of technology

Through redundant power supply design and instant response mechanism, we ensure the continuous availability of forced output functions, enhance the overall reliability of the system, and prevent production interruptions or safety hazards.

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Abstract

According to the forced output device provided by the invention, through the design of the independent power supply module, the device can continuously supply power when a power supply of a main PLC system fails, and the continuous availability of a forced output function is ensured. The redundancy design enhances the overall reliability of the system, and prevents production interruption or potential safety hazards caused by power interruption. The built-in forced signal generation module of the device can quickly generate a forced signal according to a preset condition or a remote instruction, and the forced signal is quickly transmitted to controlled equipment through the switch module. The instant response mechanism enables the system to quickly take action in emergency situations, such as emergency shutdown or switching of production modes, thereby minimizing loss.

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Description

Technical Field

[0001] This application relates to the technical field of electronic circuits, and more particularly, to a forced output device. Background Art

[0002] In the current field of industrial automation, the forced output technology plays a crucial role, and its application scope extends far beyond simple PLC bodies or single output terminals. With the rapid development of intelligent manufacturing, the forced output technology has been deeply integrated into various automation control systems, becoming a key means to ensure the stable operation of production lines and quickly respond to abnormal conditions. For example, in a complex production line control system, a PLC (programmable logic controller) can directly control various actuators such as relays, solenoid valves, and motor drivers through its powerful forced output function to achieve precise regulation of the production process. In addition, this technology is also widely used in safety systems, such as the forced disconnection of emergency stop buttons, to ensure that the source of danger can be quickly cut off in case of emergency, protecting personnel and equipment safety.

[0003] Regarding the limitations of the forced output function of the PLC body, indeed, this function highly depends on the health status of the PLC itself and a stable power supply. When the PLC is operating normally and the power supply is sufficient, it can accurately execute the preset forced output instructions to ensure the smooth progress of the production process. However, once the PLC encounters a fault or loses power, its forced output function will immediately fail, which may lead to the stagnation of the production line and even cause more serious production accidents. Summary of the Utility Model

[0004] The purpose of the embodiments of this application is to provide a forced output device to solve the technical problem that the forced output function cannot be achieved when the PLC encounters a fault or loses power.

[0005] A forced output device provided by the embodiments of this application is used to output a forced signal to a controlled device. The forced output device includes: a power module, a forced signal generation module, and a switch module;

[0006] The positive terminal of the power module is connected to the power input terminal of the switch module. The signal input terminal of the switch module is connected to the output terminal of the forced signal generation module. The power output terminal of the switch module is connected to the negative terminal of the power module. The signal output terminal of the switch module is connected to the controlled device.

[0007] In the above technical solution, through the independent power module design, the device can continue to supply power when the main PLC system power supply fails, ensuring the continuous availability of the forced output function. This redundant design enhances the overall reliability of the system and prevents production interruptions or safety hazards caused by power outages. The built-in forced signal generation module of the device can quickly generate forced signals according to preset conditions or remote instructions and quickly transmit them to the controlled devices through the switch module. This instant response mechanism enables the system to take prompt actions in case of emergencies, such as emergency shutdown or switching production modes, thereby minimizing losses to the greatest extent. The design of the switch module allows for flexible configuration of different controlled devices. Whether they are relays, solenoid valves or other types of actuators, they can be made compatible through simple wiring changes. In addition, as production requirements change, the functions of the device can be enhanced through software upgrades or module expansions to meet diverse industrial automation needs.

[0008] In some alternative embodiments, the switch module includes: a first switch, a first diode, a second diode, and a third diode;

[0009] The first end of the first switch is connected to the positive terminal of the power module, the second end of the first switch is connected to the first end of the first diode, the second end of the first diode is connected to the first end of the second diode, the second end of the second diode is connected to the first end of the third diode, and the second end of the third diode is connected to the controlled device.

[0010] In some alternative embodiments, the first switch is configured to: control the output of 16-channel forced signals when the first switch is turned on.

[0011] In some alternative embodiments, the switch module further includes: a second switch;

[0012] The first end of the second switch is connected to the positive terminal of the power module, and the second end of the second switch is connected to the first end of the second diode.

[0013] In some alternative embodiments, the second switch is configured to: control the output of 4-channel forced signals when the first switch is off and the second switch is on.

[0014] In some alternative embodiments, the switch module further includes: a light-emitting diode and a resistor;

[0015] The first end of the light-emitting diode is connected to the second end of the second diode, the second end of the light-emitting diode is connected to the first end of the resistor, and the second end of the resistor is connected to the negative terminal of the power module.

[0016] In some alternative embodiments, the power module is a 24V DC power supply. Description of the Drawings

[0017] To more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the accompanying drawings required for the embodiments of the present application. It should be understood that the following drawings only show certain embodiments of the present application and should not be regarded as limiting the scope. For those of ordinary skill in the art, without creative efforts, other related drawings can also be obtained based on these drawings.

[0018] Figure 1 Schematic diagram of the functional modules of a forced output device provided for the embodiments of the present application;

[0019] Figure 2 Circuit structure diagram of the switch module provided for the specific embodiments of the present application.

[0020] Icons: 1 - Power supply module, 2 - Forced signal generation module, 3 - Switch module, 4 - Controlled device. Detailed implementation manners

[0021] The following will describe the technical solutions in the embodiments of the present application in conjunction with the accompanying drawings in the embodiments of the present application.

[0022] Please refer to Figure 1 , Figure 1 which is a schematic diagram of the functional modules of a forced output device provided for the embodiments of the present application. The forced output device is used to output a forced signal to the controlled device 4. The forced output device includes: a power supply module 1, a forced signal generation module 2, and a switch module 3;

[0023] The positive terminal of the power supply module 1 is connected to the power input terminal of the switch module 3. The signal input terminal of the switch module 3 is connected to the output terminal of the forced signal generation module 2. The power output terminal of the switch module 3 is connected to the negative terminal of the power supply module 1. The signal output terminal of the switch module 3 is connected to the controlled device 4.

[0024] In the embodiments of the present application, through the design of the independent power supply module 1, the device can continue to supply power when the main PLC system power fails, ensuring the continuous availability of the forced output function. This redundant design enhances the overall reliability of the system and prevents production interruptions or safety hazards caused by power outages. The built-in forced signal generation module 2 of the device can quickly generate a forced signal according to preset conditions or remote instructions and quickly transmit it to the controlled device 4 through the switch module 3. This instant response mechanism enables the system to take immediate action in case of emergencies, such as emergency shutdown or switching production modes, thereby minimizing losses to the greatest extent. The design of the switch module 3 allows for flexible configuration of different controlled devices 4. Whether it is a relay, a solenoid valve or other types of actuators, compatibility can be achieved through simple wiring changes. In addition, as production requirements change, the function of the device can be enhanced through software upgrades or module expansions to meet diverse industrial automation needs.

[0025] In some alternative embodiments, the switch module 3 includes: a first switch, a first diode, a second diode, and a third diode;

[0026] A first end of the first switch is connected to the positive terminal of the power supply module 1, a second end of the first switch is connected to a first end of the first diode, a second end of the first diode is connected to a first end of the second diode, a second end of the second diode is connected to a first end of the third diode, and a second end of the third diode is connected to the controlled device 4.

[0027] In some alternative embodiments, the first switch is configured to: control the output of a 16-channel forced signal when the first switch is turned on.

[0028] In some alternative embodiments, the switch module 3 further includes: a second switch;

[0029] A first end of the second switch is connected to the positive terminal of the power supply module 1, and a second end of the second switch is connected to a first end of the second diode.

[0030] In some alternative embodiments, the second switch is configured to: control the output of a 4-channel forced signal when the first switch is turned off and the second switch is turned on.

[0031] In some alternative embodiments, the switch module 3 further includes: a light-emitting diode and a resistor;

[0032] A first end of the light-emitting diode is connected to a second end of the second diode, a second end of the light-emitting diode is connected to a first end of the resistor, and a second end of the resistor is connected to the negative terminal of the power supply module 1.

[0033] In some alternative embodiments, the power supply module 1 is a 24V DC power supply.

[0034] Please refer to Figure 2 , Figure 2 , which is the circuit structure diagram of the switch module provided by the specific embodiment of the present application. The forced output device of this embodiment uses a 24V DC power supply. The switch module of this embodiment is designed on a PCB. The node XT0 of the PCB is connected to the negative terminal of the 24V DC power supply and led to the terminal on the PCB. The node XT1 of the PCB is connected to the positive terminal of the 24V DC power supply and led to the terminal on the PCB. Among them, XT1-1, XT1-2, XT1-3, XT1-4, and XT1-5 are connected in parallel inside the PCB board. The node XT2 of the PCB is the forced signal access point and is led to the terminal on the PCB. The node XT3 of the PCB is the forced signal output point and is led to the terminal on the PCB.

[0035] Specifically, the node XT1-1 is connected to the positive terminal of the 24V DC power supply, and the node XT1-1 is connected to the node XT2-1 through a switch;

[0036] The node XT2-1 is connected to the input end of the diode D1. The output end of the diode D1 is connected to the input end of the diode D17. The output end of the diode D17 is connected to the input end of the diode D33. The output end of the diode D33 is connected to the node XT3-1. The node XT3-1 outputs the forced signal of channel 01 to the corresponding controlled device. The output end of the diode D17 is also connected to the input end of the light-emitting diode H1. The output end of the light-emitting diode H1 is connected to the first end of the resistor R1. The second end of the resistor R1 is connected to the node XT0. The node XT0 is connected to the negative pole of the 24V DC power supply.

[0037] The node XT2-1 is connected to the input end of the diode D2. The output end of the diode D2 is connected to the input end of the diode D18. The output end of the diode D18 is connected to the input end of the diode D34. The output end of the diode D34 is connected to the node XT3-2. The node XT3-2 outputs the forced signal of channel 02 to the corresponding controlled device. The output end of the diode D18 is also connected to the input end of the light-emitting diode H2. The output end of the light-emitting diode H2 is connected to the first end of the resistor R2. The second end of the resistor R2 is connected to the node XT0. The node XT0 is connected to the negative pole of the 24V DC power supply.

[0038] The node XT2-1 is connected to the input end of the diode D3. The output end of the diode D3 is connected to the input end of the diode D19. The output end of the diode D19 is connected to the input end of the diode D35. The output end of the diode D35 is connected to the node XT3-3. The node XT3-3 outputs the forced signal of channel 03 to the corresponding controlled device. The output end of the diode D19 is also connected to the input end of the light-emitting diode H3. The output end of the light-emitting diode H3 is connected to the first end of the resistor R3. The second end of the resistor R3 is connected to the node XT0. The node XT0 is connected to the negative pole of the 24V DC power supply.

[0039] The node XT2-1 is connected to the input end of the diode D4. The output end of the diode D4 is connected to the input end of the diode D20. The output end of the diode D20 is connected to the input end of the diode D36. The output end of the diode D36 is connected to the node XT3-4. The node XT3-4 outputs the forced signal of channel 04 to the corresponding controlled device. The output end of the diode D20 is also connected to the input end of the light-emitting diode H4. The output end of the light-emitting diode H4 is connected to the first end of the resistor R4. The second end of the resistor R4 is connected to the node XT0. The node XT0 is connected to the negative pole of the 24V DC power supply.

[0040] The input terminal of diode D5 is connected to node XT2-1. The output terminal of diode D5 is connected to the input terminal of diode D21. The output terminal of diode D21 is connected to the input terminal of diode D37. The output terminal of diode D37 is connected to node XT3-5. Node XT3-5 outputs the forced signal of channel 05 to the corresponding controlled device. The output terminal of diode D21 is also connected to the input terminal of light-emitting diode H5. The output terminal of light-emitting diode H5 is connected to the first end of resistor R5. The second end of resistor R5 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0041] The input terminal of diode D6 is connected to node XT2-1. The output terminal of diode D6 is connected to the input terminal of diode D22. The output terminal of diode D22 is connected to the input terminal of diode D38. The output terminal of diode D38 is connected to node XT3-6. Node XT3-6 outputs the forced signal of channel 06 to the corresponding controlled device. The output terminal of diode D22 is also connected to the input terminal of light-emitting diode H6. The output terminal of light-emitting diode H6 is connected to the first end of resistor R6. The second end of resistor R6 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0042] The input terminal of diode D7 is connected to node XT2-1. The output terminal of diode D7 is connected to the input terminal of diode D23. The output terminal of diode D23 is connected to the input terminal of diode D39. The output terminal of diode D39 is connected to node XT3-7. Node XT3-7 outputs the forced signal of channel 07 to the corresponding controlled device. The output terminal of diode D23 is also connected to the input terminal of light-emitting diode H7. The output terminal of light-emitting diode H7 is connected to the first end of resistor R7. The second end of resistor R7 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0043] The input terminal of diode D8 is connected to node XT2-1. The output terminal of diode D8 is connected to the input terminal of diode D24. The output terminal of diode D24 is connected to the input terminal of diode D40. The output terminal of diode D40 is connected to node XT3-8. Node XT3-8 outputs the forced signal of channel 08 to the corresponding controlled device. The output terminal of diode D24 is also connected to the input terminal of light-emitting diode H8. The output terminal of light-emitting diode H8 is connected to the first end of resistor R8. The second end of resistor R8 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0044] Node XT2-1 is connected to the input terminal of diode D9. The output terminal of diode D9 is connected to the input terminal of diode D25. The output terminal of diode D25 is connected to the input terminal of diode D41. The output terminal of diode D41 is connected to node XT3-9, and node XT3-9 outputs the forced signal of channel 09 to the corresponding controlled device. The output terminal of diode D25 is also connected to the input terminal of light-emitting diode H9. The output terminal of light-emitting diode H9 is connected to the first terminal of resistor R9. The second terminal of resistor R9 is connected to node XT0, and node XT0 is connected to the negative pole of the 24V DC power supply.

[0045] Node XT2-1 is connected to the input terminal of diode D10. The output terminal of diode D10 is connected to the input terminal of diode D26. The output terminal of diode D26 is connected to the input terminal of diode D42. The output terminal of diode D42 is connected to node XT3-10, and node XT3-10 outputs the forced signal of channel 10 to the corresponding controlled device. The output terminal of diode D26 is also connected to the input terminal of light-emitting diode H10. The output terminal of light-emitting diode H10 is connected to the first terminal of resistor R10. The second terminal of resistor R10 is connected to node XT0, and node XT0 is connected to the negative pole of the 24V DC power supply.

[0046] Node XT2-1 is connected to the input terminal of diode D11. The output terminal of diode D11 is connected to the input terminal of diode D27. The output terminal of diode D27 is connected to the input terminal of diode D43. The output terminal of diode D43 is connected to node XT3-11, and node XT3-11 outputs the forced signal of channel 11 to the corresponding controlled device. The output terminal of diode D27 is also connected to the input terminal of light-emitting diode H11. The output terminal of light-emitting diode H11 is connected to the first terminal of resistor R11. The second terminal of resistor R11 is connected to node XT0, and node XT0 is connected to the negative pole of the 24V DC power supply.

[0047] Node XT2-1 is connected to the input terminal of diode D12. The output terminal of diode D12 is connected to the input terminal of diode D28. The output terminal of diode D28 is connected to the input terminal of diode D44. The output terminal of diode D44 is connected to node XT3-12, and node XT3-12 outputs the forced signal of channel 12 to the corresponding controlled device. The output terminal of diode D28 is also connected to the input terminal of light-emitting diode H12. The output terminal of light-emitting diode H12 is connected to the first terminal of resistor R12. The second terminal of resistor R12 is connected to node XT0, and node XT0 is connected to the negative pole of the 24V DC power supply.

[0048] Node XT2-1 is connected to the input terminal of diode D13. The output terminal of diode D13 is connected to the input terminal of diode D29. The output terminal of diode D29 is connected to the input terminal of diode D45. The output terminal of diode D45 is connected to node XT3-13. Node XT3-13 outputs the forced signal of channel 13 to the corresponding controlled device. The output terminal of diode D29 is also connected to the input terminal of light-emitting diode H13. The output terminal of light-emitting diode H13 is connected to the first terminal of resistor R13. The second terminal of resistor R13 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0049] Node XT2-1 is connected to the input terminal of diode D14. The output terminal of diode D14 is connected to the input terminal of diode D30. The output terminal of diode D30 is connected to the input terminal of diode D46. The output terminal of diode D46 is connected to node XT3-14. Node XT3-14 outputs the forced signal of channel 14 to the corresponding controlled device. The output terminal of diode D30 is also connected to the input terminal of light-emitting diode H14. The output terminal of light-emitting diode H14 is connected to the first terminal of resistor R14. The second terminal of resistor R14 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0050] Node XT2-1 is connected to the input terminal of diode D15. The output terminal of diode D15 is connected to the input terminal of diode D31. The output terminal of diode D31 is connected to the input terminal of diode D47. The output terminal of diode D47 is connected to node XT3-15. Node XT3-15 outputs the forced signal of channel 15 to the corresponding controlled device. The output terminal of diode D31 is also connected to the input terminal of light-emitting diode H15. The output terminal of light-emitting diode H15 is connected to the first terminal of resistor R15. The second terminal of resistor R15 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0051] Node XT2-1 is connected to the input terminal of diode D16. The output terminal of diode D16 is connected to the input terminal of diode D32. The output terminal of diode D32 is connected to the input terminal of diode D48. The output terminal of diode D48 is connected to node XT3-16. Node XT3-16 outputs the forced signal of channel 16 to the corresponding controlled device. The output terminal of diode D32 is also connected to the input terminal of light-emitting diode H16. The output terminal of light-emitting diode H16 is connected to the first terminal of resistor R16. The second terminal of resistor R16 is connected to node XT0. Node XT0 is connected to the negative pole of the 24V DC power supply.

[0052] The node XT1-2 is connected to the positive pole of the 24V DC power supply. After passing through a switch, the node XT1-2 is connected to the nodes XT2-2, XT2-3, XT2-4, and XT2-5; the node XT2-2 is connected to the input end of the diode D17, the node XT2-3 is connected to the input end of the diode D18, the node XT2-4 is connected to the input end of the diode D19, and the node XT2-5 is connected to the input end of the diode D20;

[0053] The node XT1-3 is connected to the positive pole of the 24V DC power supply. After passing through a switch, the node XT1-3 is connected to the nodes XT2-6, XT2-7, XT2-8, and XT2-9; the node XT2-6 is connected to the input end of the diode D21, the node XT2-7 is connected to the input end of the diode D22, the node XT2-8 is connected to the input end of the diode D23, and the node XT2-9 is connected to the input end of the diode D24;

[0054] The node XT1-4 is connected to the positive pole of the 24V DC power supply. After passing through a switch, the node XT1-4 is connected to the nodes XT2-10, XT2-11, XT2-12, and XT2-13; the node XT2-10 is connected to the input end of the diode D25, the node XT2-11 is connected to the input end of the diode D26, the node XT2-12 is connected to the input end of the diode D27, and the node XT2-13 is connected to the input end of the diode D28;

[0055] The node XT1-5 is connected to the positive pole of the 24V DC power supply. After passing through a switch, the node XT1-5 is connected to the nodes XT2-14, XT2-15, XT2-16, and XT2-17; the node XT2-14 is connected to the input end of the diode D29, the node XT2-14 is connected to the input end of the diode D30, the node XT2-15 is connected to the input end of the diode D31, and the node XT2-16 is connected to the input end of the diode D32.

[0056] In the embodiments provided in the present application, it should be understood that the disclosed devices and methods can be implemented in other ways. The device embodiments described above are merely illustrative. For example, the division of the units is only a logical function division. In actual implementation, there may be other division methods. For another example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections between each other can be through some communication interfaces. The indirect couplings or communication connections of the devices or units can be electrical, mechanical or other forms.

[0057] In addition, the units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0058] Furthermore, in each embodiment of the present application, the functional modules may be integrated together to form an independent part, or each module may exist alone, or two or more modules may be integrated to form an independent part.

[0059] In this document, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations.

[0060] The above description is only for the embodiments of the present application and is not intended to limit the protection scope of the present application. For those skilled in the art, the present application may have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A forced output device, characterized in that: The forced output device is used to output a forced signal to the controlled device, and the forced output device includes: a power supply module, a forced signal generating module, and a switch module; The positive end of the power module is connected to the power input end of the switch module, the signal input end of the switch module is connected to the output end of the forced signal generating module, the power output end of the switch module is connected to the negative end of the power module, and the signal output end of the switch module is connected to the controlled device.

2. The forced output device according to claim 1, characterized in that: The switch module includes: a first switch, a first diode, a second diode and a third diode; The first end of the first switch is connected to the positive end of the power module, the second end of the first switch is connected to the first end of the first diode, the second end of the first diode is connected to the first end of the second diode, the second end of the second diode is connected to the first end of the third diode, and the second end of the third diode is connected to the controlled device.

3. The forced output device according to claim 2, characterized in that: The first switch is used to control the forced signal output of 16 channels when the first switch is turned on.

4. The forced output device according to claim 2, characterized in that: The switch module further includes: a second switch; A first end of the second switch is connected to the positive end of the power module, and a second end of the second switch is connected to the first end of the second diode.

5. The forced output device according to claim 4, characterized in that: The second switch is used to control the forced signal output of the four channels when the first switch is turned off and the second switch is turned on.

6. The forced output device according to claim 2, characterized in that: The switch module also includes: a light emitting diode and a resistor; The first end of the light emitting diode is connected to the second end of the second diode, the second end of the light emitting diode is connected to the first end of the resistor, and the second end of the resistor is connected to the negative end of the power module.

7. The forced output device according to claim 1, characterized in that: The power supply module is a 24V DC power supply.