Non-Invasive PLC Analog I/O Monitoring via Integrated Display
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Solution Overview
Problem
Current monitoring methods for analog I/O modules in Programmable Logic Controllers (PLCs) are invasive, costly, and delay the monitoring process, often causing skewed data due to the need for external meters and computers, which can disrupt the automation process and require invasive procedures.
Innovation Solution
A non-invasive device that directly connects an I/O card to a display interface, allowing real-time monitoring of analog I/O data, including voltage, current, and temperature, without altering the system, using a simple button navigation system to view data in digital counts and engineering units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external meters and computers are used to monitor PLC outputs, then monitoring capability is provided, but the monitoring process becomes invasive and costly, and data accuracy deteriorates due to system disruption
Solution Approach 1:
The patent combines the monitoring display functionality directly with the PLC's existing I/O card and processor unit. The display interface is integrated into the controller housing, and the I/O card is modified to include display driver circuitry. This merging eliminates the need for separate external meters and computers, providing accurate monitoring without invasive connections while reducing overall system complexity.
2Loss of time
If external monitoring devices are connected to PLC I/O modules, then data can be read, but the monitoring process causes time delays and increases cost
Solution Approach 1:
The patent extracts the display functionality from external monitoring equipment and integrates it directly into the PLC controller. The display interface is built into the controller housing, and the I/O card is modified to include display driver circuitry. This extraction eliminates the need for separate external monitoring devices, thereby eliminating the time delays and costs associated with external connections while maintaining the ability to read and monitor data.
3Reliability
If invasive monitoring methods are used to read PLC outputs, then monitoring is achieved, but the automation process is disrupted and data quality deteriorates
Solution Approach 1:
The patent combines the monitoring display functionality directly with the PLC's existing I/O card and processor unit. The display interface is integrated into the controller housing, and the I/O card is modified to include display driver circuitry. This merging allows monitoring to occur without invasive external connections, thereby maintaining automation process reliability while keeping the monitoring operation simple and straightforward.
Data Source
AI summary
A device that provides for the non-invasive data monitoring of analog IO of a Programmable Logic Controller (PLC) system. The output is ultimately displayed on an interface in real-time and is measured directly from the IO channel. This type of device allows the accurate reading and analysis of errors and erroneous data within a device and transmission of said data to disparate secondary devices for use.