Low-Cost PLC Design Using MCU and Anti-Jamming Circuits
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Solution Overview
Problem
Highly reliable and stable programmable logic controllers (PLCs) are expensive, making them costly for controlling simple machine actions, which increases manufacturing costs.
Innovation Solution
A cost-effective PLC design utilizing an Intel MCS-51 series SOC single-chip as the core, combined with a DC power module, I/O module, relay output module, and pulse output module, with a system program that includes a programming module and control module to simplify programming and control operations, while maintaining stability and reliability through anti-jamming circuits and optical coupling devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive high-reliability PLCs are used to control machines, then stability and reliability are improved, but manufacturing costs increase
Solution Approach 1:
The patent replaces expensive traditional PLC components with a low-cost microcontroller unit (MCU) that can be easily replaced if needed. The MCU-based design achieves sufficient reliability for simple control tasks without requiring costly industrial-grade PLC hardware, directly addressing the cost-reliability tradeoff.
Solution Approach 2:
The patent substitutes traditional PLC control architecture with a simplified MCU-based system. This replacement eliminates complex PLC hardware while maintaining control functionality through software programming, significantly reducing manufacturing costs while preserving adequate reliability for simple machine control operations.
2Stability of the object's composition
If simple machines are controlled with high-reliability PLCs, then control stability is improved, but product costs increase
Solution Approach 1:
The patent applies control stability locally through software-based control algorithms programmed in the MCU rather than requiring high-stability hardware throughout the entire system. This localized approach to stability maintenance allows simple machines to be controlled reliably without the need for expensive PLC hardware, reducing overall product cost.
Solution Approach 2:
The patent changes the control parameter from hardware-based PLC processing to software-based MCU processing. This parameter change allows the system to achieve sufficient control stability through programmable logic and control algorithms, eliminating the need for expensive high-stability PLC hardware and thereby reducing product cost.
Data Source
AI summary
A PLC includes a single-chip, a DC power module, a relay output module, an I/O module, and a pulse output module. The single chip includes a single-chip timer, a hardware watchdog, a 11.0592M crystal, and an A/D converter module. A system program is burned into an EEPROM (Electrically Erasable Programmable Read-Only Memory) of the single-chip. The system program includes a programming module and a control module. A DC power module includes an anti jamming circuit, a first output port, and a second output port. The first output port and the second output port are respectively connected to the anti-jamming circuit, and the single-chip is connected to the first output port. A relay output module is connected to the second output port. An I/O module receives and sends digital signals.