Integrated Temperature Control Module for PLC Slot Reduction
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Solution Overview
Problem
Conventional temperature control systems require multiple slots on a PLC base for separate analogue input, PID control, and output modules, leading to increased costs, complexity, and inefficiency due to the need for multiple modules for different sensors and slow scan speeds affecting control functions.
Innovation Solution
An integral-type temperature control module that integrates input, control, and output functions, using a single module to convert analogue signals into digital signals, perform PID control, and output modulated values through Pulse Width Modulation (PWM) signals, reducing the need for multiple modules and simplifying the control path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate analogue input module, PID control module, and analogue output module are used, then temperature control function is achieved, but the number of PLC base slots increases and system complexity increases
Solution Approach 1:
The patent combines the analogue input module, PID control module, and analogue output module into a single integrated temperature control module. This merging eliminates the need for multiple separate modules, reducing the number of PLC base slots required from three to one, while maintaining all necessary temperature control functions including signal conversion, PID calculation, and output control.
Solution Approach 2:
The integrated temperature control module performs multiple functions within a single device: it converts analogue temperature signals to digital values, executes PID control algorithms, and generates control outputs. This multi-functional design allows one module to replace three separate modules, simplifying the system architecture while preserving comprehensive temperature control capabilities.
2Adaptability or versatility
If multiple modules are used for different sensor types, then various temperature sensors can be connected, but the number of required modules increases and costs increase
Solution Approach 1:
The integrated module incorporates multiple input circuit sectors designed to accept different types of temperature sensor signals (thermocouple, RTD, resistance, voltage, current). By building this multi-functional capability into a single module, the system can handle various sensor types without requiring separate dedicated modules for each sensor type, thereby reducing both the number of modules and overall system cost.
3Reliability
If separate modules are used for input, control, and output, then signal processing is distributed, but scan speed decreases and control performance is affected
Solution Approach 1:
By integrating the input signal conversion, PID control processing, and output signal generation into a single module with a unified control path, the patent eliminates the time delays associated with inter-module communication and data transfer. This consolidation enables faster scan speeds and improved real-time control performance while maintaining the完整性 of the control function.
Data Source
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AI summary
Disclosed are a temperature control module (420) and a method thereof. An analogue input module, a PID control module, and an analogue output module are integrated as one module. The temperature control method comprises: determining a type of an analogue signal input to an input means (100) from preset parameters so as to control a temperature of an object; converting the analogue signal to a digital signal based on the type of the analogue signal; performing a PID control based on a measured temperature value of the digital signal and a predetermined target value thereby calculating a modulated value; generating a control signal of a pulse width modulation (PWM) control signal based on the modulated value and the preset parameter; and outputting the modulated value according to the PWM control signal.