Modular PLC Expansion Detection for Easier Configuration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Industrial controller systems are complex and difficult for non-technical users to configure and troubleshoot due to multiple layers of technology, making it challenging to expand, update, and identify issues within the systems, especially when dealing with interconnected PLCs and expansion modules.

Innovation Solution

An industrial controller system with a controller device that automatically detects and identifies connected expansion modules using a 'daisy chaining' algorithm, providing a graphical user interface to visualize the configuration and allowing for easy setup and troubleshooting, and enabling remote management and monitoring through a cloud dashboard.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple layers of technology devices are used in industrial control systems, then functionality and capability are improved, but system complexity and difficulty of configuration increase

Engineering Contradiction:

ImprovefunctionalityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system is divided into modular components: controller devices, expansion modules, and HMI devices. Each module can be independently configured and connected, allowing functionality to be added through simple module attachment rather than complex system-wide configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A discovery service acts as an intermediary between HMI devices and controller devices. The discovery service automatically manages connections and data routing, eliminating the need for manual configuration of communication pathways between multiple technology layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If manual configuration of individual controller devices is performed, then system customization is improved, but time consumption and labor requirements increase

Engineering Contradiction:

Improvesystem customizationVSAvoidconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs self-configuration through automated discovery services. When expansion modules are connected, the discovery service automatically detects them, retrieves their capabilities, and configures communication parameters without requiring manual intervention, thus maintaining customization while eliminating time-consuming manual setup.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Expansion modules come pre-configured with their capabilities and identification information stored in memory. This preliminary preparation allows the discovery service to quickly identify and integrate modules without requiring on-site configuration, significantly reducing setup time while maintaining full customization capability.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If interconnected PLCs and expansion modules are used, then system capability is improved, but troubleshooting difficulty increases

Engineering Contradiction:

Improvesystem capabilityVSAvoidtroubleshooting difficulty

Core Design Contradiction:

Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The discovery service continuously monitors the network and provides feedback about the status of all connected devices. When a device malfunctions or is improperly connected, the system automatically detects the issue and can notify operators, making troubleshooting much easier in complex interconnected systems.

Inventive Principle:

Principle #23Feedback

4Reliability

If pre-configuration of HMI devices for specific devices is performed, then communication reliability is improved, but system flexibility and ease of expansion decrease

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidsystem flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The discovery service provides universal configuration capabilities that work with any controller device or expansion module in the system. Instead of requiring separate pre-configuration for each device pair, the discovery service automatically manages all communications, maintaining reliability while enabling easy system expansion through universal compatibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11599097B1Modular industrial controller system

Publication Date: 2023.03.07 SAMSARA INC

AI summary

A controller device may connect to one or more expansion modules for capability expansion. The controller device may be configured to automatically detect and identify connected expansions modules. The controller device may be configured to further automatically detect an order in which the expansion modules are connected. A graphical user interface may be provided including a visualization of the system configuration including the order of the expansion modules.