PLC Network Extension System Resolving Distance and Performance Constraints
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Solution Overview
Problem
The existing PLC network extension systems face limitations due to distance restrictions and performance degradation, particularly with parallel signal transmission leading to electromagnetic issues, and increased complexity in installation and programming, which hampers flexible extension and calculation speed.
Innovation Solution
A PLC network extension system utilizing a program interface similar to serial cable methods, featuring a basic base with a network cable, extension manager unit, controller, basic base interface, and module mounting unit, along with extension bases connected via network cables, allowing for independent control and scatter operations without dependency on the basic base, enhancing performance and resource efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parallel signal transmission using extension cables is employed, then control modules of extension bases can be directly controlled from CPU module, but distance restriction occurs due to electromagnetic problems
Solution Approach 1:
The patent replaces the parallel signal transmission mechanism (extension cables) with a network-based transmission mechanism. Extension bases are connected to the network via network interface units, enabling data communication without the electromagnetic limitations of cable-based parallel transmission. This substitution allows extended communication distance while maintaining control reliability.
2Adaptability or versatility
If PLC system is extended to cover large area and process large volume information, then flexible extension and calculation speed become important, but network load increases due to control message from main CPU
Solution Approach 1:
The patent divides the control system into autonomous segments where each extension base operates independently with its own controller and network interface. Extension bases can perform scatter operations and independent control without requiring continuous communication with the basic base, reducing network load and maintaining system performance as the network expands.
Solution Approach 2:
Extension bases are designed to be self-sufficient with local controllers that can execute operations independently. The controller in each extension base manages local control tasks without requiring constant intervention from the main CPU, reducing network traffic and improving overall system productivity while maintaining flexibility.
3Adaptability or versatility
If extension bases are connected via daisy chain configuration using extension cables, then system can be extended, but installation and programming complexity increases
Solution Approach 1:
The patent replaces the complex daisy-chain cable configuration with a simplified network-based connection system. Extension bases connect to the network through standard network interface units, eliminating the need for complex cable routing and configuration. This reduces both installation complexity and programming requirements while maintaining system extendability.
Data Source
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AI summary
Provided is a PLC network extension system, the system including a basic base generating a control data for controlling a plurality of extension bases, generating a network frame using the control data, and transmitting the network frame to one extension base in the plurality of extension bases via a network cable, and the plurality of extension bases extracting a control data from the received network frame to control a pre-installed module based on the control data.