Virtual I/O Module for Direct PLC Data Exchange
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Solution Overview
Problem
Existing automation systems do not support direct cyclical data exchange between programmable logic controllers (PLCs) necessary for machine coupling in production lines, as communication relationships are limited to PLCs and peripheral systems.
Innovation Solution
Incorporating a virtual I/O module in the interface module of a peripheral board, allowing output data from one PLC to be copied as input data for another PLC, enabling direct communication between control facilities without additional fieldbus boards or wiring, using existing fieldbus communication mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct cyclical data exchange between PLCs is implemented, then communication flexibility and productivity are improved, but device complexity and infrastructure requirements increase
Solution Approach 1:
The patent introduces a virtual I/O module as an intermediary component within the peripheral board that mediates direct communication between PLCs. This virtual module acts as a bridge, allowing output data from one PLC to be copied and made available as input data to another PLC without requiring direct PLC-to-PLC communication infrastructure, thus improving communication efficiency while avoiding increased system complexity
Solution Approach 2:
The patent implements data copying from the output region of one PLC to the input region of another PLC through the virtual I/O module. This copying mechanism enables direct cyclical data exchange between PLCs using existing fieldbus infrastructure, achieving improved communication flexibility without adding complex new hardware or wiring
2Adaptability or versatility
If additional fieldbus boards and wiring are added for PLC-to-PLC communication, then communication capability is improved, but cost and device complexity increase
Solution Approach 1:
The patent makes the peripheral board's interface module multi-functional by adding virtual I/O modules that enable both traditional PLC-to-peripheral communication and direct PLC-to-PLC communication. This universal approach allows the existing fieldbus infrastructure to serve multiple communication needs without requiring additional dedicated hardware boards or wiring for PLC interconnection
3Adaptability or versatility
If virtual I/O module is added to peripheral board, then PLC communication flexibility is improved, but interface module complexity increases
Solution Approach 1:
The virtual I/O module implements a simple copying function that duplicates output data from one PLC into the input region of another PLC. This copying approach provides communication flexibility without requiring complex processing or additional hardware, as it utilizes the existing I/O module structure and data pathways already present in the peripheral board
Data Source
AI summary
An automation system includes a first control facility with a first fieldbus connection, a second control facility with a second fieldbus connection, a fieldbus, a peripheral board with at least one I/O peripheral module, wherein the peripheral board has an interface module with a third fieldbus connection, where the interface module has at least one I/O module which stores interconnection information featuring an assignment of input/outputs of the I/O peripheral module(s) to the control facilities, where the interface module additionally has a virtual I/O module, in which an output region is assigned to the first control facility, and furthermore an input region is assigned to the second controller, and where the virtual I/O module is configured such that the output data is copied from the output region of the first control facility into the input region as input data for the second control facility.