PLC Override Board Remote Auto Mode Reset

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Solution Overview

Problem

Operators or service personnel may accidentally leave the manual auto/on/off switch of a Programmable Logic Controller (PLC) in the 'on' or 'off' position, requiring costly and time-consuming service calls to correct, especially when accessing difficult locations.

Innovation Solution

An electronic solution that allows remote reconfiguration of the manual auto/on/off switch back to 'auto' mode through a user interface or automatic programming by the PLC, eliminating the need for physical access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a manual auto/on/off switch is used on the PLC for controlling individual outputs, then manual control capability is improved, but the risk of accidental misconfiguration and the cost/time for correction increases

Engineering Contradiction:

Improvemanual control capabilityVSAvoidtime for correction

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system automatically detects when a manual switch position causes a problem and self-corrects by sending a command to return the switch to the previous position, eliminating the need for service personnel to physically access and correct the switch

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system monitors the state of manual switches and provides feedback to the PLC, enabling automatic detection of problematic configurations and triggering appropriate corrective actions through the user interface

Inventive Principle:

Principle #23Feedback

2Ease of operation

If a manual auto/on/off switch is used on the PLC for controlling individual outputs, then manual control capability is improved, but the complexity of the system increases

Engineering Contradiction:

Improvemanual control capabilityVSAvoidsystem complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The override board integrates multiple functions including manual switching, automatic detection, electronic communication with the PLC, and user interface capabilities into a single device, reducing overall system complexity while maintaining manual control capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The override board acts as an intermediary between the manual switch and the PLC, handling the complexity of detection and correction logic while presenting a simple interface to operators

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If service personnel must physically access the controller to correct manual switch positions, then reliability of correction is improved, but the ease of repair deteriorates

Engineering Contradiction:

Improvecorrection reliabilityVSAvoidease of correction

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The system replaces the need for mechanical physical access to switches with electronic detection and control mechanisms, allowing correction to be performed remotely through the user interface while maintaining reliability through automated detection and confirmation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10440827B2Programmable logic controller override

Publication Date: 2019.10.08 KMC CONTROLS

AI summary

An override board of a programmable logic controller includes a manual switch such as a push button for manual selection between a first “auto” mode where the output is controlled by the programmable logic controller, a second mode where the output is energized, and a third mode where the output is de-energized. The override board can be switched back to the “auto” mode electronically, without physically obtaining access to the controller and without moving the manual switch. The override clear signal is preferably provided on a power connection with the programmable logic controller and to a microprocessor on the override board which controls the output mode.