PLC Power Unit Status Data Transmission via Shared Bus
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Solution Overview
Problem
Conventional programmable logic controller (PLC) devices lack a data transmission path between the PLC main body and the power unit, preventing the utilization of lifetime data generated by the power unit within the PLC system without external wiring, which can lead to incapacitation if the power unit fails due to secular degradation.
Innovation Solution
A programmable controller device with a CPU unit and power unit connected by a bus line, featuring a data transmission path that allows status data from the power unit to be transmitted to a user-accessible memory area within the CPU, enabling the PLC main body to directly utilize this data without external wiring, and allowing for various applications in user or system programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a data transmission path is added between the PLC main body and power unit, then the PLC main body can directly utilize status data from the power unit, but the device complexity increases
Solution Approach 1:
The patent merges the data transmission functionality into the existing bus line infrastructure. The power unit and PLC main body share common signal lines (power supply lines, ground lines, or control signal lines) to transmit status data, eliminating the need for separate dedicated data transmission paths and reducing overall system complexity.
Solution Approach 2:
Existing bus lines in the PLC system are made multi-functional by enabling them to carry both power supply/control signals and status data transmission. This allows the same physical infrastructure to serve multiple purposes, avoiding additional wiring while enabling data communication between the power unit and PLC main body.
2Loss of information
If external wiring is provided to transmit lifetime data from the power unit, then the data can be utilized by the PLC main body, but the ease of operation deteriorates
Solution Approach 1:
The patent combines data transmission functionality with existing power supply or control signal lines. Status data such as lifetime information is transmitted by modulating these existing lines, eliminating the need for separate external wiring and simplifying system installation and operation.
Solution Approach 2:
The patent uses existing bus lines as intermediaries to transfer status data from the power unit to the PLC main body. These existing lines act as mediators that already provide the necessary physical connection, avoiding the need for additional external wiring while enabling data communication.
3Reliability
If the power unit fails due to secular degradation, then the PLC main body becomes incapacitated, but no proactive measures can be taken without data transmission capability
Solution Approach 1:
The patent implements feedback by transmitting status data (including lifetime information) from the power unit back to the PLC main body. This enables the system to monitor power unit health in real-time and take proactive measures before failure occurs, improving reliability and preventing unexpected incapacitation.
Solution Approach 2:
The patent enables preliminary action by making lifetime data accessible to the PLC main body before actual failure occurs. This allows the system to perform preventive maintenance, replace components proactively, or switch to backup power units before the power unit fails, avoiding system incapacitation.
Data Source
AI summary
A programmable controller device has a main body with a CPU unit and I/O units connected by a bus line and a power unit for supplying power to the main body. The CPU unit has a memory with a user access area which is accessible by instruction of user program. The power unit generates status data related to itself such as its temperature. A data transmission path is provided between the CPU unit and the power unit for transmitting such status data to the user access area.