USB PLC Control System for PC-Based Automation Reliability
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Solution Overview
Problem
The high rate of innovation in PC-based control technology leads to significant maintenance costs and compatibility issues due to the need for frequent adaptations with new software versions and PC generations, resulting in lower reliability and increased dependence on specific hardware and software configurations.
Innovation Solution
A flexible communication and control structure, implemented using a USB-based programmable logic controller (PLC) that operates independently of the host PC's operating system, allowing for easy installation and configuration, and enabling the use of standard interfaces to reduce hardware and software dependencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PC-based control technology is used with standard operating systems, then software versatility and open interfaces are improved, but reliability deteriorates due to influence from other PC programs and lack of real-time capability
Solution Approach 1:
The system is divided into two independent parts: a PC running a standard operating system for user interface and configuration, and a separate PLC (programmable logic controller) for real-time control tasks. This segmentation allows each component to specialize in its strength while maintaining communication through standardized interfaces.
Solution Approach 2:
A communication interface acts as an intermediary between the PC and PLC, using standardized protocols to exchange data and commands. This mediator ensures reliable control execution while maintaining software versatility on the PC side.
2Ease of manufacture
If automation components are integrated as pure software on PC, then additional hardware costs are reduced, but reliability and real-time performance deteriorate
Solution Approach 1:
The control system separates software-based PC functions from hardware-based PLC functions, allowing the PLC to provide reliable real-time control with minimal hardware while the PC handles higher-level tasks.
Solution Approach 2:
The PLC operates independently with its own processor and memory, executing control tasks without requiring continuous PC intervention, thus ensuring reliable operation even when the PC is unavailable.
3Adaptability or versatility
If control technology is adapted to new PC generations and software versions, then compatibility with current systems is improved, but maintenance costs and complexity increase
Solution Approach 1:
The system allows dynamic adaptation where the PC side can be updated independently to match new operating systems and interfaces, while the PLC maintains stable, proven control logic that doesn't require frequent updates.
Solution Approach 2:
The PLC uses standardized communication protocols that ensure universal compatibility across different PC generations and operating systems, reducing the need for custom adaptations when upgrading hardware or software.
4Manufacturing precision
If fieldbus interface modules are used to ensure real-time capability, then control precision is improved, but device complexity and hardware costs increase
Solution Approach 1:
The real-time control functionality is extracted from the complex PC environment and placed in a dedicated, simplified PLC that handles only control tasks, reducing overall system complexity while maintaining precision.
Data Source
AI summary
In automation engineering, in general the PLC function is implemented into the device that only exchanges control and status information with the higher level unit. This is generally done through different serial communication interfaces based on field bus or Ethernet standards. In order to enable a control system with flexible communication and control structure and to enable the configuration thereof, the system comprises: a data processing unit (PC) comprising at least two or more communications interfaces (U, E), an information medium (UE) that can be connected to the first communication interface (U), said medium comprising a microcontroller (MC), a program memory (PM) and a data storage medium (DM) and a bus cable that can be connected to the second communication interface (E) for connection of devices (ID, OD) communicating together by way of a serial data bus (FES), so that the information medium (UE) with integrated microcontroller (MC) implements a free-programmable sequential control and so that through connection to the first communication interface (U) of the data processing unit (PC), the data processing unit can be expanded with the aid of communication drivers (UD, ED) of the first and second communication interface (U, E) using the data processing unit (PC) as a communication platform for free-programmable control. The invention is used in the field of control systems.