PLC Signal Cable Tag Reader for Automated State Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for checking the connection state of signal cables in systems controlled by a programmable logic controller (PLC) are inefficient, as they require manual measurement and comparison of voltage levels and temporary switching of output signals, and cannot easily determine the state of input or output signals without prior signal assignment identification.
Innovation Solution
A PLC maintenance support device and program that uses a signal identification tag reader to read signal addresses from cables, transmit these addresses to the PLC, and receive the on/off states, displaying them for easy monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual voltage measurement and comparison methods are used to check signal cable connections, then measurement capability is achieved, but operation time and efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical voltage measurement with an automated signal reading system. The signal cable connection checking device automatically reads signal names from mark tubes using optical recognition, queries the PLC for corresponding signal states, and displays results without manual voltage measurement, thereby substituting mechanical/electrical manual operations with automated electronic systems.
Solution Approach 2:
The system enables self-service by allowing the device to automatically query its own PLC controller for signal states and automatically display results. The PLC maintenance support device independently performs the entire checking process without requiring external manual intervention for voltage measurement and comparison.
2Loss of information
If signal addresses are manually identified from mark tubes and PLC screens are manually checked, then signal identification is achieved, but operation complexity and time increase
Solution Approach 1:
The patent merges multiple separate operations into a single integrated device. The signal cable connection checking device combines mark tube reading, PLC querying, and result display functions into one unified system, eliminating the need to separately check mark tubes and PLC screens manually.
Solution Approach 2:
The checking device performs multiple functions: it reads signal names from mark tubes, identifies corresponding signal addresses, queries PLC for signal states, and displays results. This multi-functional device replaces multiple separate manual operations, improving both ease of operation and information retrieval efficiency.
3Reliability
If output signals are temporarily switched on/off to check connections, then connection verification is achieved, but system stability and operation continuity are affected
Solution Approach 1:
The patent performs preliminary identification of signal addresses and states before any switching operations. By reading mark tubes and querying PLC for current signal states in advance, the system establishes a baseline that allows connection verification without requiring temporary signal switching, thus maintaining system stability.
Solution Approach 2:
The system replaces the mechanical action of temporarily switching signals on/off with electronic information retrieval. By querying the PLC for signal states and comparing with mark tube information, the system achieves connection verification without physical signal manipulation, maintaining operational stability.
Data Source
AI summary
A PLC maintenance support device according to the present invention includes a signal identification tag reader for reading a signal address from a signal identification tag attached to an input and output signal cable of a PLC to identify the signal address of the input and output signal cable, a transmitter for transmitting the signal address identified by the signal identification tag reader to the PLC, a receiver for receiving the on or off state of a signal corresponding to the transmitted signal address from the PLC, and a monitor for displaying the received on or off state of the signal.