Programmable Controller Slot Switching for Empty Module Bypass

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Solution Overview

Problem

Conventional programmable controllers cannot perform forward and backward communication effectively when there are empty slots between modules, limiting their applicability in communication systems.

Innovation Solution

A programmable controller design with a master module at one end and slave modules at the other, utilizing forward and backward switching units to bypass communication wirings when empty slots are present, ensuring continuous communication by short-circuiting or disconnecting wires accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If modules are mounted with empty slots between them in a conventional programmable controller, then the configuration flexibility is improved, but the communication reliability deteriorates because forward and backward communication cannot be performed effectively

Engineering Contradiction:

Improveconfiguration flexibilityVSAvoidcommunication reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The communication path is segmented into forward communication path and backward communication path, with separate switching units (forward switching unit and backward switching unit) controlling each path independently. This segmentation allows the system to maintain communication reliability by selectively bypassing empty slots in each direction while supporting flexible module configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The forward switching unit and backward switching unit act as intermediaries between modules, dynamically routing communication signals around empty slots. These switching units enable communication continuity by switching between direct module connections and bypass paths through the base unit, resolving the contradiction between configuration flexibility and communication reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If switching units are added to enable communication with empty slots, then the communication reliability is improved, but the device complexity increases

Engineering Contradiction:

Improvecommunication reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The switching units are designed with multi-functionality, serving both as communication relays and as configuration management elements. Each switching unit can operate in multiple states (connecting adjacent modules, bypassing through base unit, or disconnecting), allowing a single component to handle various communication scenarios without requiring separate dedicated components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The forward switching unit and backward switching unit are integrated into the slot connector structure, merging the switching functionality with the existing mechanical and electrical connection infrastructure. This consolidation reduces overall device complexity by eliminating separate switching mechanisms while maintaining the ability to bypass empty slots for reliable communication.

Inventive Principle:

Principle #5Merging (Combining)

3Speed

If communication wirings are continuously connected between all slots, then the communication speed is maintained, but the noise interference increases when empty slots are present

Engineering Contradiction:

Improvecommunication speedVSAvoidnoise interference

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The communication wiring configuration is made dynamic through the switching units, which can change connection states based on module presence. When modules are detected in adjacent slots, the switching units establish direct high-speed connections. When empty slots are detected, the switching units dynamically reconfigure to bypass through the base unit, maintaining communication while reducing noise interference from disconnected or floating wiring.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The electrical connection parameters (conductivity, impedance) are changed dynamically by the switching units based on module configuration. By switching between direct connection mode and bypass mode, the system optimizes signal transmission parameters to maintain high communication speed while minimizing noise from unused or floating wiring in empty slots.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9804641B2Programmable controller

Publication Date: 2017.10.31 JTEKT CORP

AI summary

A programmable controller includes forward switching units and backward switching units. The forward switching units electrically disconnect forward communication wirings if a module is mounted on a slot connector, and electrically short-circuits the forward communication wirings if no module is mounted on the slot connector. The backward switching units electrically disconnect backward communication wirings if the module is mounted on the slot connector, and electrically short-circuits the backward communication wirings if no module is mounted on the slot connector.