PLC RJ45 I/O Interface Layout for Space-Efficient Expansion
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Solution Overview
Problem
Conventional Programmable Logic Controllers (PLCs) face challenges in expanding or maintaining input/output interfaces due to space constraints and wiring complexity, primarily because of the size of terminal blocks and power supply units.
Innovation Solution
A PLC design featuring a master unit connected to interface units via a system bus, utilizing RJ45 terminals for data input/output, allowing for flexible expansion by arranging multiple signals per pin and simplifying wiring through RJ45 connections, which also includes a separate COM terminal for common signal lines to maximize input/output channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal blocks are used for input/output interfaces, then reliable signal connection is achieved, but space efficiency deteriorates and wiring complexity increases
Solution Approach 1:
The RJ45 terminal is designed to serve multiple functions: it provides reliable signal connection like traditional terminal blocks, enables flexible wiring through standardized connectors, supports multiple signal configurations (8 signals per pin), and allows easy expansion by adding more terminals. This multi-functional design resolves the contradiction by achieving reliable connection while improving space efficiency and reducing wiring complexity.
Solution Approach 2:
The invention changes the connection parameter from conventional terminal blocks to RJ45 connectors, which have different physical characteristics (smaller size, standardized pin arrangement). This parameter change enables more compact wiring harnesses and better space utilization while maintaining connection reliability through the standardized 8-pin interface.
2Reliability
If conventional terminal blocks are used for input/output interfaces, then stable signal connection is achieved, but wiring complexity increases
Solution Approach 1:
The RJ45 terminal serves as a universal connector that simplifies wiring through standardized interfaces. The same RJ45 connector type is used throughout the system, allowing consistent connection methods across different signal types and reducing the variety of connection techniques needed, thereby reducing overall wiring complexity while maintaining stable connections.
Solution Approach 2:
The wiring system is segmented into modular RJ45 connectors that can be independently configured and connected. Each RJ45 terminal handles specific signal groups, allowing the wiring to be divided into manageable segments rather than requiring complex continuous wiring harnesses, thus reducing overall wiring complexity.
3Adaptability or versatility
If more input/output channels are added to conventional PLC, then functionality is improved, but space consumption increases
Solution Approach 1:
Each RJ45 terminal provides 8 signal channels through a single connector, maximizing the use of available space. By utilizing all 8 pins of each RJ45 connector for signal transmission, the system achieves high I/O density without proportionally increasing physical space consumption, enabling flexible expansion while maintaining space efficiency.
4Area of stationary object
If RJ45 terminals with 8 signals per pin are used, then space efficiency is improved, but signal management complexity increases
Solution Approach 1:
The signal management system is segmented and organized by grouping signals according to their function and connection pattern. The control unit processes signals in organized groups corresponding to the RJ45 terminal configurations, making it easier to manage the complexity of 8 signals per pin through systematic organization rather than handling all signals as a single complex set.
Data Source
AI summary
A PLC according to an embodiment of the present invention is disclosed. The PLC according to an embodiment of the present invention comprises: a master unit; and a plurality of interface units which access the master unit via a system bus. The master unit includes: a control unit for controlling input/output and processing commands; and a plurality of first RJ45 terminals for input/output of data, wherein a maximum of eight signals are arranged via each pin of each of the first RJ45 terminals. Each of the interface units includes a connection means for connecting a signal between a second RJ45 terminal for connecting a signal line from each of the first RJ45 terminals and an external device, wherein the interface units are configured to be expandable by the number of the first RJ45 terminals.