PLC Module Cartridge and Container Segmentation

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Solution Overview

Problem

The complexity of managing and maintaining programmable logic controllers (PLCs) in industrial environments is exacerbated by the need for various form factors and types of electrical interfaces, leading to increased inventory and maintenance challenges due to the multitude of product variations required for different applications.

Innovation Solution

A modular assembly for PLCs comprising a container and a cartridge, where the cartridge provides electronic functions and can be removably inserted into different form factor containers, allowing for flexible selection of mechanical form factor and electronic functionality, reducing inventory needs and simplifying maintenance by enabling replacement of only the cartridge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If various form factors and types of electrical interfaces are provided for different applications, then the PLC can adapt to different industrial environments, but the complexity of managing and maintaining PLCs increases due to the multitude of product variations

Engineering Contradiction:

Improveadaptability to different industrial environmentsVSAvoidcomplexity of managing and maintaining PLCs

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The PLC module is divided into two separate components: a container that provides the mechanical form factor and electrical interfaces, and a cartridge that provides the electronic functionality. This segmentation allows each component to be independently designed and optimized, reducing the complexity of managing multiple product variations while maintaining adaptability to different industrial environments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cartridge is designed to be universally compatible with multiple containers of different form factors. A single cartridge can be inserted into various containers to serve different applications, eliminating the need for multiple specialized products and simplifying inventory management and maintenance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple product variations are provided to address different application requirements, then the PLC can meet diverse industrial needs, but the inventory requirements and spare parts storage needs increase

Engineering Contradiction:

Improveability to meet diverse industrial needsVSAvoidinventory requirements and spare parts storage

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

A single cartridge design can serve multiple applications by being inserted into different containers. This universality dramatically reduces the number of unique products that need to be inventoried and stored as spare parts, while still meeting diverse industrial needs through container-cartridge combinations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the common electronic functionality (cartridge) with multiple application-specific form factors (containers). This combination approach allows a single cartridge to replace multiple specialized modules, reducing inventory requirements and spare parts storage needs.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If traditional modular designs are used where the entire module must be replaced for maintenance, then system reliability is maintained, but maintenance time and operational disruption increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmaintenance time and operational disruption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The separation of the cartridge (electronic function) from the container (mechanical housing) enables independent replacement of the cartridge without affecting the container or other system components. This segmentation allows for rapid maintenance by replacing only the faulty cartridge, minimizing operational disruption while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cartridge is extracted as a separate, removable component from the container. This extraction allows the cartridge to be easily removed and replaced without disassembling the entire module or container, significantly reducing maintenance time and operational disruption while preserving system reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentEP3209101B1Module for a logic controller

Publication Date: 2020.04.08 SCHNEIDER ELECTRIC IND SAS

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AI summary

The invention relates to a modular assembly of a module for a Logic Controller, comprising a container and a cartridge. The cartridge has a first electrical interface part and an electronic circuit arranged to provide a predetermined electronic function. The container has a housing, a backplane connector, a terminal connector and a receptacle extending inside the housing and adapted to receive the cartridge. The receptacle includes a second electrical interface part adapted to connect with the first electrical interface part. The cartridge and the receptacle are arranged to electrically connect the first and second electrical interface parts to establish an electrical interface when the cartridge is removably inserted in the receptacle of the container. The housing of the container defines the mechanical form factor of the module, while the cartridge determines the electronic functionality of the module. Accordingly, multiple containers having different form factors may accommodate the same cartridge.