PLC Data Converter Using Statistical Sampling Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing data converters that communicate with programmable logic controllers (PLCs) face challenges in maintaining high sampling density and control accuracy due to increased communication overhead and processing stress, especially when oversampling, which also results in inconvenient user data processing requirements.
Innovation Solution
A data converter that performs multiple samplings within a communication period and transmits statistical data, such as maximum, minimum, and average values, rather than raw data, to improve sampling density and reduce data transmission, thereby alleviating PLC processing load and user inconvenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the data converter performs sampling multiple times in one communication period, then the sampling density is improved, but the communication overhead and PLC processing stress are increased
Solution Approach 1:
The patent extracts only the essential statistical information (maximum, minimum, average values) from the multiple sampling data points, transmitting only these extracted features to the PLC rather than all raw sampling data. This reduces communication overhead while preserving the benefits of high-density sampling for control accuracy.
Solution Approach 2:
The data converter performs preliminary data processing and statistical analysis locally before transmission, calculating maximum, minimum, and average values in advance. This preliminary action reduces the burden on the PLC by pre-processing the data, allowing the PLC to receive ready-to-use statistical information rather than raw data requiring extensive processing.
2Loss of information
If the data converter transmits all sampling results to the PLC, then the sampling information is complete, but the data transmission amount increases
Solution Approach 1:
The patent extracts only the most representative statistical features (maximum, minimum, average values) from the complete sampling data set. These extracted features capture the essential information about the sampled signal characteristics while representing a minimal subset of the total data, thus reducing transmission amount while maintaining information completeness for control purposes.
Solution Approach 2:
The patent transforms the raw sampling data into different parameter representations (statistical parameters such as max, min, average) that convey the same essential information in a compressed form. This parameter transformation maintains the informational value needed for control while significantly reducing the data volume that must be transmitted.
3Measurement precision
If the user processes large amounts of raw sampling data, then the data analysis is thorough, but the user convenience decreases
Solution Approach 1:
The data converter performs self-service by automatically calculating and preparing statistical data (maximum, minimum, average values) before transmission. This self-service functionality eliminates the need for users to perform complex data processing operations, making the system easier to use while still providing thorough analytical information through the pre-computed statistical parameters.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A data converter, a signal transmission method, and a signal transmission system for transmitting a signal to a programmable logic controller are provided. The data converter: performs sampling a plurality of number of times with respect to data detected by a sensor in one communication period in which communication is performed with a programmable logic controller; acquires statistical data by maintaining statistics of a plurality of pieces of sampling data in the communication period; and transmits the statistical data to the programmable logic controller when the communication period is reached. On the basis of an embodiment of the present invention, a signal sampling density is improved, and thus control accuracy can be enhanced. At the same time, a data transmission amount of a bus is reduced, a load on the programmable logic controller is reduced, and user convenience is improved.