Virtual Data Record Module for PLC Fieldbus Communication
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Solution Overview
Problem
Existing automation systems do not support direct cyclic data exchange between multiple programmable logic controllers, which is necessary for coupling machines in a production line, as communication relationships are only set up between controllers and peripheral systems.
Innovation Solution
Implementing a virtual data record module in the interface module that allows control devices to communicate directly through multiple accesses to data record channels, enabling point-to-point communication between control devices without requiring additional fieldbus assemblies or wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If communication relationships are only set up between controllers and peripheral systems, then the system structure remains simple and established, but direct cyclic data exchange between multiple programmable logic controllers is not supported
Solution Approach 1:
The patent introduces a virtual data record module as an intermediary mechanism within the peripheral system that enables indirect communication between controllers. This virtual module acts as a mediator that receives data from one controller and makes it accessible to another controller, thereby enabling direct cyclic data exchange between PLCs without requiring additional communication infrastructure or complex wiring changes.
2Adaptability or versatility
If additional fieldbus assemblies or wiring are added to enable PLC-PLC communication, then direct communication between controllers is achieved, but system complexity and costs increase
Solution Approach 1:
The patent makes the peripheral system's data record channels serve multiple functions: they continue to handle traditional peripheral I/O communication while simultaneously enabling direct PLC-PLC communication. The virtual data record module utilizes existing data record channels and communication infrastructure for dual purposes, eliminating the need for separate dedicated communication paths between controllers.
Solution Approach 2:
The patent creates a virtual copy of data records within the peripheral system's memory structure. The virtual data record module copies or references data from one controller's data record channel and makes it accessible to another controller, enabling data exchange without physical duplication of communication hardware or wiring.
3Adaptability or versatility
If virtual data record modules are implemented in the peripheral system, then flexible fieldbus communication between controllers is enabled, but the complexity of the peripheral system increases
Solution Approach 1:
The patent merges the PLC communication functionality directly into the existing peripheral system structure. The virtual data record module is integrated within the peripheral system's data processing architecture, combining I/O handling and controller communication functions into a unified structure that shares common resources such as data record channels and processing logic.
Data Source
Figure 1~3
AI summary
The invention relates to an automation system (50) comprising: - a first control unit (1) with a first fieldbus connection (31), - a second control unit (2) with a second fieldbus connection (32), - a fieldbus (3), - a peripheral assembly (10) with at least one input/output peripheral module (11) for connecting sensors and/or actuators, wherein the peripheral assembly (10) has an interface module (20) with a third fieldbus connection (33) for communication to and/or from the control units (1, 2), wherein the interface module (20) has at least one input/output module (21) in which wiring information is stored, wherein the wiring information includes an assignment of inputs/outputs of the input/output peripheral module(s) (11) to the control units (1, 2), wherein the interface module (20) additionally has a virtual data record module (22).in which a data record receiver module (40) is assigned to the first control unit (1), into which the first control unit (1) can write a data record (60), and furthermore, a data record transmitter module (42) is assigned to the second control unit (2) within the data record module (22), from which the second control unit (2) can retrieve the data record (60), the virtual data record module being designed such that the data record (60) is copied from the data record receiver module (40) to the data record transmitter module (42), thereby realizing a communication path between the control units (1,2).