Programmable Controller Output Module Common Circuit Control
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Solution Overview
Problem
Conventional output modules for programmable controllers require complex control programs and increased capacity when all load output circuits need to be turned OFF simultaneously, as they lack a mechanism to interrupt the continuity between the external power supply and the output common terminal, leading to increased program complexity.
Innovation Solution
Incorporating an output common output circuit that can be controlled ON/OFF by the control circuit, allowing a single OFF instruction to be sent to the output common output circuit to turn OFF all load output circuits, eliminating the need for individual instructions and simplifying the control program, while also including a monitoring circuit to detect overvoltage, disconnection, overcurrent, or ground faults and a forcible-OFF circuit to quickly stop power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual OFF instructions are sent to each load output circuit, then all circuits can be turned OFF simultaneously, but the control program becomes complex and requires increased program capacity
Solution Approach 1:
The patent introduces an output common output circuit as an intermediary component that receives a single OFF instruction from the control circuit and distributes it to all load output circuits. This mediator eliminates the need for complex individual control instructions while ensuring simultaneous disconnection of all circuits, directly resolving the contradiction between reliability and program complexity.
2Reliability
If an open/close mechanism is added to the output common terminal, then simultaneous disconnection is achieved, but the device structure becomes more complex and requires additional components
Solution Approach 1:
The patent merges the output common output circuit functionality directly into the output module's control circuit architecture. Instead of adding a separate open/close mechanism as an external component, the control circuit integrates the common output control function, achieving simultaneous disconnection while minimizing structural complexity and avoiding additional standalone components.
3Reliability
If multiple control mechanisms are added for fault monitoring, then system safety is enhanced, but the device complexity increases
Solution Approach 1:
The control circuit is designed with multi-functionality, serving both as the main control unit for load output circuits and as the fault monitoring system. The same control circuit detects abnormalities such as overcurrent, overvoltage, and ground faults without requiring separate dedicated monitoring devices, thereby enhancing system safety while avoiding increased structural complexity.
Data Source
AI summary
An output module for programmable controller includes an output common output circuit that supplies load current to each of the load output circuits, and the control circuit controls ON/OFF of the output common output circuit in accordance with an instruction from the higher-level device.