Ladder Diagram Circuit Replacement for Readable PLC Logic
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Solution Overview
Problem
As ladder diagram programs scale, repeated partial circuits increase complexity, reducing readability and debugging efficiency due to their composition of multiple contacts.
Innovation Solution
A device that selects and replaces repeated partial circuits with fewer contacts, inserting auxiliary circuits to maintain functionality, thereby improving readability and debugging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the same partial circuit is repeatedly used in a ladder diagram program, then the program functionality is maintained, but the program complexity increases and readability decreases
Solution Approach 1:
The patent applies segmentation by dividing the ladder diagram program into distinct circuit blocks. Each repeated partial circuit is identified and extracted as a separate block that can be independently managed and referenced multiple times, reducing overall program complexity while maintaining functionality.
Solution Approach 2:
The patent implements universality by creating reusable circuit blocks that can be instantiated multiple times throughout the program. A single block definition serves multiple functions by being referenced in different locations, reducing redundancy and improving readability without sacrificing program functionality.
2Reliability
If the same partial circuit is repeatedly used in a ladder diagram program, then the program functionality is maintained, but debugging efficiency is reduced
Solution Approach 1:
By segmenting the program into distinct circuit blocks, the patent enables independent debugging of each block. Problems can be isolated to specific blocks rather than searching through repeated instances of partial circuits, significantly improving debugging efficiency while maintaining program functionality.
Solution Approach 2:
The patent implements feedback mechanisms that allow operators to monitor and debug circuit blocks independently. When a block is executed multiple times, the system provides feedback about each instance's execution status, enabling efficient identification and resolution of issues without affecting other parts of the program.
3Reliability
If multiple contacts are used in a partial circuit, then the circuit functionality is achieved, but the number of contacts increases complexity
Solution Approach 1:
The patent applies merging by combining multiple contacts into a single circuit block. Instead of displaying and managing each contact individually across multiple instances, the contacts are merged into a unified block that can be referenced repeatedly, reducing the apparent complexity while maintaining the underlying circuit functionality.
Data Source
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AI summary
A partial circuit selection unit selects a partial circuit comprising a plurality of contacts in a ladder diagram program. A replacement circuit generation unit generates a replacement circuit comprising a smaller number of contacts than in the selected partial circuit. An auxiliary circuit generation unit generates an auxiliary circuit that causes the replacement circuit to perform the same action as the partial circuit. A program editing unit performs, on the ladder diagram program, a replacement process for replacing a partial circuit appearing in the ladder diagram program with the replacement circuit, and performs an auxiliary circuit insertion process for inserting the auxiliary circuit into the ladder diagram program.