PLC Network Load Sharing via Synchronized Auxiliary Controllers
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Solution Overview
Problem
In network systems, extending the hardware capability of a programmable logic controller (PLC) to manage increased loads often requires either replacing the PLC with a higher-performance model or dividing the network, which involves significant investment and synchronization challenges.
Innovation Solution
The solution involves using an existing PLC as both a main and an auxiliary device, connected via a high-speed/synchronization network, allowing the auxiliary PLC to assist the main PLC in processing tasks beyond its capacity without the need for network division or new design, by reallocating tasks through a load simulator to maintain synchronization and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the PLC is changed to another PLC having a higher performance, then the processing capacity is improved, but the equipment investment increases
Solution Approach 1:
The existing PLC is made to perform multiple functions by operating in both master and auxiliary modes. The same hardware platform is utilized for different roles (master PLC and auxiliary PLC) through software configuration, eliminating the need for additional high-performance equipment while maintaining enhanced processing capacity.
Solution Approach 2:
The functionality of a master PLC and an auxiliary PLC is merged into a single existing PLC system. By enabling the same PLC to operate as both master and auxiliary devices simultaneously, the system combines the capabilities of multiple units without requiring additional hardware investment.
2Productivity
If the network system is divided, then the load distribution is improved, but the system complexity increases
Solution Approach 1:
The same PLC model serves dual purposes as both master and auxiliary devices within the unified network system. This multi-functionality approach enables load distribution across different operational roles without requiring separate physical systems or complex division of the network infrastructure.
Solution Approach 2:
The system dynamically allocates processing loads between master and auxiliary functions based on real-time requirements. The existing PLC can flexibly switch between and combine master and auxiliary operations, enabling adaptive load distribution without rigid system division or complex reconfiguration.
3Productivity
If the network system is divided, then the processing capacity is improved, but the synchronization difficulty increases
Solution Approach 1:
By keeping the network system unified rather than divided, the patent eliminates synchronization challenges between separate systems. The same PLC operating in multiple roles within a single network maintains inherent synchronization, avoiding the complexity of coordinating multiple independent network segments.
Data Source
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AI summary
A network system includes: a first master device configured to carry out, in every cycle, (i) a process of receiving data from a first slave device, (ii) a process of carrying out, in accordance with pre-allocation, a part of a first process with respect to the data which has been received, (iii) a process of transmitting data corresponding to a remainder of the first process to an outside entity in accordance with the pre-allocation and receiving a result corresponding the remainder of the first process, and (iv) a process of transmitting, to the first slave device, a result corresponding to the first process; at least one second master device configured to transmit, to the first master device before a period allocated to the first process within the cycle ends, the result corresponding to the remainder of the first process with respect to the data received from the first master device; a first network configured to transmit data between the first slave device and the first master device; and a second network configured to transmit data between the first master device and the at least one second master device.