Description
4000056-002 TRICONEX controller
4000056-002 TRICONEX controller
Module Clips Drive controller servo motor
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What IO combinations can a mini PLC combine with to achieve automated control?
At present, there are two main design modes for controllers like PLC, one is integrated design and the other is modular design. From the name, we can feel that there are two different PLCs, one that cannot be disassembled and the other that can be disassembled. Due to the fact that the main control module and IO module of the modular PLC can be spliced as needed, its volume and weight are usually very small, and we cannot call it a mini PLC too much. So, what IO combinations can such a small gadget combine with to achieve automation control? Let”s take a brief inventory:4000056-002 TRICONEX controller
1. Firstly, there is the digital quantity acquisition IO module, which is used to collect digital quantity information. Typical examples include counter IO, PNP type digital quantity acquisition IO, NPN type digital quantity acquisition IO, etc.
2. Then there is the digital output IO module, which is used to send digital instructions. The most typical example is PWM output IO, which can output pulse signals to control servo motors or stepper motors for operation.
3. After talking about digital IO, let”s talk about analog IO. Analog signal acquisition type IO includes voltage signal acquisition, current signal acquisition, and temperature signal acquisition. The IO for collecting temperature signals includes PT100, PT1000, and various thermocouple temperature acquisition modules.
4. Finally, there are analog output IO, as well as output current signals and voltage signals.
In addition to the above IO modules, our modular PLC also supports extended communication interfaces, further enhancing the equipment”s scalability.
Module Input/Output (I/O) Knowledge4000056-002 TRICONEX controller
Module Input/Output (I/O) Knowledge
I think it”s necessary to talk about the sorting of the input and output ports of the module. Generally, we can divide it into IO functional division and IO specifications.
The purpose of the former is mainly to convert all functions into actual division into MCU IO ports, while the purpose of the latter is to determine the specifications of all IO ports. Of course, you can completely skip these tasks, and it”s also possible. Depending on the company”s requirements, I think individuals still consider them as a work habit.
The following examples are all created for my blog post. If there are any duplicate names, please do not contact me.
Looking at the above figure, first determine all input and output functions and power input, as well as communication.
Then separate the power distribution with different lines, and start organizing each power supply line and processing process. The final purpose of the entire diagram is to clearly allocate the input and output sequence.
The IO specification is to provide a detailed description of all interfaces, crystal oscillators, and other information to the MCU.
1. Enter the number of low effective interfaces and how much pull-up resistance (switch wet current) is required (how much current does the microcontroller need to absorb, which may be injected into the microcontroller after pull-up).
2. Enter the number of highly effective interfaces, how many pull-down resistors are required (switch wet current), (how much current does the microcontroller need to absorb, and it is possible to inject the microcontroller after the switch is effective)
3. Number of analog input interfaces, evaluate whether the analog ports of the microcontroller are sufficient, and confirm the required analog conversion accuracy. Evaluate whether the A/D conversion reference voltage needs to be replaced (to meet accuracy requirements). Consider how many power supplies need to be tested and how many analog input ports are configured.
4. Evaluate the requirements for crystal oscillator accuracy and whether a phase-locked loop is required.
The above requirements are mainly aimed at module design and need to be confirmed during the early development of the module. All requirements can be organized using an Excel table and displayed in the diagram.
Distributed dual Ethernet IO module
The distributed dual Ethernet IO module adopts an industrial grade design, which meets the demanding industrial application scenarios. It is equipped with a dedicated high-performance Ethernet chip, which can quickly achieve cascade networking between IO modules without the need for repeated wiring, saving on-site wiring costs.
The distributed dual Ethernet IO module comes with switch input, switch output, relay output, analog input, analog input, thermal resistance input, etc. It supports high-speed pulse input counting and high-speed pulse output, and is designed specifically for industrial field data collection, measurement, and control. The distributed dual Ethernet IO module supports Modbus TCP protocol and Modbus RTU protocol for uplink, which can quickly connect to existing DCS, SCADA, PLC, HMI and other systems. The distributed dual Ethernet IO module supports one RS485 interface and supports Modbus RTU Master function. It can expand the IO module, read and write intelligent instrument data, or connect to HMI, DCS, PLC and other devices as a Modbus Slave.
Modify the watchdog time of the PROFINET IO device under 16 STEP7
3.2 Check if the installation of PROFINET IO communication equipment meets the specifications
Most cases of PROFINET IO communication interference problems are caused by equipment installation that does not comply with the installation specifications for PROFINET IO communication, such as incomplete shielding, unreliable grounding, and being too close to interference sources. Installation that meets the specifications can avoid communication failures caused by electromagnetic interference. You can refer to the following brief installation requirements for PROFINET:
1. Wiring of PROFINET 4000056-002 TRICONEX controller
In order to reduce the coupling of electric and magnetic fields, the larger the parallel distance between PROFINET and other power cable interference sources, the better. In accordance with IEC 61918, the minimum distance between PROFINET shielded cables and other cables can be referred to Table 1. PROFINET 4000056-002 TRICONEX controller can be wired together with other data cables, network cables, and shielded analog cables. If it is an unshielded power cable, the minimum distance is 200mm.
Comprehensive analysis of the principle and application skills of microcontroller IO port
IO port operation is the most basic and important knowledge in microcontroller practice. This article takes a long time to introduce the principles of IO ports. I also consulted a lot of materials to ensure the accuracy of the content, and spent a long time writing it. The principle of IO ports originally required a lot of in-depth knowledge, but here it has been simplified as much as possible for easy understanding. This will be of great help in solving various IO port related problems in the future.
The IO port equivalent model is my original method, which can effectively reduce the difficulty of understanding the internal structure of the IO port. And after consulting and confirming, this model is basically consistent with the actual working principle.
I mentioned a lot earlier, and many people may already be eager to actually operate microcontrollers. The IO port, as the main means of communication between the microcontroller and the outside world, is the most basic and important knowledge for microcontroller learning. Previously, we programmed and implemented an experiment to light up the LED at the IO port. This article will continue to introduce the relevant knowledge of the IO port.
In order to better learn the operation of IO ports, it is necessary to understand the internal structure and related concepts of IO ports. These knowledge are very helpful for subsequent learning, with a focus on understanding and no need to memorize them intentionally. If you don”t remember, just come back and take a look. If you use it too much, you will naturally remember.
We have said that the most accurate and effective way to understand a chip is to refer to official chip manuals and other materials. But for beginners of microcontrollers, it may be difficult to understand the chip manual directly, especially when they see a bunch of English, unfamiliar circuits, and terminology. If it were me, I would definitely be crazy. But here I still provide a picture taken from Atmel”s official “Atmel 8051 Microcontrollers Hardware Manual”.
The purpose of giving this picture is not to dampen everyone”s enthusiasm for learning, but to help everyone understand how the various microcontroller materials we have seen come from and whether they are accurate. All of these can be clarified through official information, which will be helpful for everyone to further learn something in the future.
Introduction to the Second Function
The above figure is the authoritative 51 microcontroller IO port structure diagram provided by the official. It can be seen that the internal structure of the four sets of IO ports of the microcontroller is different, because some IO ports have a secondary function, as mentioned in the introductory section.
Do you remember this pin diagram? The second function name of the IO port is marked in parentheses. Except for P1, each interface has a second function. When introducing the microcontroller system module, I mentioned that the 51 microcontroller has an interface for reserved extended memory, which is the second function of P0 and P1 in the figure (while also using pins such as 29 and 30). Because it is not widely used and involves in-depth knowledge, no specific research will be conducted. By the way, the AD0~AD7 we see here are actually used for parallel ports. The second function of the P3 port, including serial port, will be introduced in detail later.
The drawbacks of network IO and the advantages of multiplexing IO
In order to talk about multiplexing, of course, we still need to follow the trend and adopt a whiplash approach. First, we will talk about the drawbacks of traditional network IO and use the pull and step method to grasp the advantages of multiplexing IO.
For the convenience of understanding, all the following code is pseudo code, and it is sufficient to know the meaning it expresses.
Blocking IO
The server wrote the following code to handle the data of client connections and requests.
Listenfd=socket()// Open a network communication port
Bind (listenfd)// binding
Listen (listenfd)// Listening while (1){
Connfd=accept (listenfd)// Blocking connection establishment
Int n=read (connfd, buf)// Blocking read data
DoSomeThing (buf)// What to do with the data you read
Close (connfd)// Close the connection and wait for the next connection in a loop
}
This code will be executed with stumbling blocks, just like this.
It can be seen that the thread on the server is blocked in two places, one is the accept function and the other is the read function.
If we expand on the details of the read function again, we will find that it is blocked in two stages.
This is traditional blocking IO.
The overall process is shown in the following figure.
So, if the client of this connection continues to not send data, the server thread will continue to block on the read function and not return, nor will it be able to accept other client connections.
This is definitely not feasible.
Non blocking IO
To solve the above problem, the key is to modify the read function.
A clever approach is to create a new process or thread every time, call the read function, and perform business processing.
While (1){
Connfd=accept (listenfd)// Blocking connection establishment
Pthread_ Create (doWork)// Create a new thread
}
Void doWork(){
Int n=read (connfd, buf)// Blocking read data
DoSomeThing (buf)// What to do with the data you read
Close (connfd)// Close the connection and wait for the next connection in a loop
}
In this way, once a connection is established for a client, it can immediately wait for a new client connection without blocking the read request from the original client.
However, this is not called non blocking IO, it just uses multithreading to prevent the main thread from getting stuck in the read function and not going down. The read function provided by the operating system is still blocked.
So true non blocking IO cannot be achieved through our user layer tricks, but rather by imploring the operating system to provide us with a non blocking read function.
The effect of this read function is to immediately return an error value (-1) when no data arrives (reaches the network card and is copied to the kernel buffer), rather than waiting for blocking.
The operating system provides this feature by simply setting the file descriptor to non blocking before calling read.
Fcntl (connfd, F_SETFL, O_NONBLOCK);
Int n=read (connfd, buffer)= SUCCESS;
In this way, the user thread needs to loop through the call to read until the return value is not -1, and then start processing the business.
We noticed a detail here.
Non blocking read refers to the stage where data is non blocking before it reaches the network card, or before it reaches the network card but has not been copied to the kernel buffer.
When the data has reached the kernel buffer, calling the read function is still blocked and requires waiting for the data to be copied from the kernel buffer to the user buffer before returning.
The overall process is shown in the following figure
IO multiplexing
Creating a thread for each client can easily deplete the thread resources on the server side.
Of course, there is also a clever solution. After accepting each client connection, we can put the file descriptor (connfd) into an array.
Fdlist. add (connfd);
Then create a new thread to continuously traverse the array and call the non blocking read method for each element.
While (1){
For (fd “- fdlist){
If (read (fd)!=- 1){
DoSomeThing();
}
}
}
In this way, we successfully processed multiple client connections with one thread.
Do you think this means some multiplexing?
But this is just like using multithreading to transform blocked IO into seemingly non blocking IO. This traversal method is just a small trick that our users have come up with, and every time we encounter a read that returns -1, it is still a system call that wastes resources.
Making system calls in a while loop is not cost-effective, just like making rpc requests while working on distributed projects.
So, we still need to plead with the operating system boss to provide us with a function that has such an effect. We will pass a batch of file descriptors to the kernel through a system call, and the kernel layer will traverse them to truly solve this problem.
Application Scheme of Industrial Ethernet Remote IO Module in Intelligent Manufacturing Workshop
With the advent of Industry 4.0, intelligent manufacturing has become a trend in industrial production. Intelligent manufacturing requires efficient, stable, and reliable industrial Ethernet remote IO modules to monitor the production process. This article will share an application case of an intelligent manufacturing workshop based on industrial Ethernet remote IO module.4000056-002 TRICONEX controller
The production process of this intelligent manufacturing workshop is mainly divided into two parts: injection molding and automated assembly. The injection molding process requires controlling parameters such as the melting temperature of the melt, the speed and pressure of the injection molding machine. The automated assembly process requires controlling the actions of the assembly robot and detecting the quality of the product. In addition to these production process data, there are also equipment production data such as daily and weekly production in the workshop, as well as equipment status data such as operation, manual, automatic, mold adjustment, and alarm.
In the past, the production process of the factory mainly relied on traditional hard wiring to control the production process, resulting in low work efficiency due to the need for frequent replacement of transmission lines to meet production needs. Moreover, it is very difficult to collect a large number of types of detection and monitoring data for intelligent manufacturing. In order to improve efficiency, production quality, and reliability, the factory has introduced the industrial Ethernet remote IO module MxxT using barium rhenium technology.
The injection molding machine itself comes with MODBUS industrial control bus data or basic status signal output. The barium rhenium technology remote IO module collects data from the device interface RS232/RS485 port, collects status information of the injection molding machine such as startup, operation, and pause, and uploads it to the injection molding machine controller, or wirelessly uploads it to the cloud server. Based on devices, according to the communication protocols and interfaces of different devices, data is obtained by calling their interface channels, and then transmitted to the server.
The remote IO module is connected to the controller of the injection molding machine, and the operation data of the injection molding machine is uploaded and distributed wirelessly, achieving remote monitoring and intelligent control of the injection molding machine. In addition, the remote I/O module supports perceptual access to peripheral devices such as mold temperature machines, cutting machines, and dryers for injection molding machines, providing users with smart factory services.
During the injection molding process, the industrial Ethernet remote IO module transmits real-4000056-002 TRICONEX controllertime data such as temperature, pressure, and speed to the main controller for monitoring and adjustment, ensuring the stability and compliance of production parameters under different conditions. In the automated assembly process, the industrial Ethernet remote IO module collects data through sensors and other devices, and transmits the relevant data to the main controller for adjustment of relevant actions. For example, the industrial Ethernet remote IO module can monitor the actions of assembly robots, detect the accuracy of product assembly and product quality, and ensure the production quality and stability of the product. At the same time, all production data can also be collected and analyzed remotely, helping enterprise managers better monitor production efficiency and quality.
By introducing industrial Ethernet remote IO modules, this intelligent manufacturing workshop not only improves production efficiency and stability, but also reduces labor and energy costs. Because the industrial Ethernet remote IO module can help enterprises complete the collection and monitoring of production data with one click, as well as avoid unnecessary line replacement and the need for workers to enter and exit the production process, thereby reducing costs and improving production efficiency for enterprises.
In summary, the application of industrial Ethernet remote IO modules in intelligent manufacturing workshops not only improves production efficiency and quality, reduces costs, but also achieves intelligent and digital management of production processes, bringing more opportunities and development space for enterprise development.
In addition, this device is widely used for networking and data collection of industrial equipment such as injection molding machines, air compressors, CNC machine tools, on-site PLCs, instruments, sensors, CNC, and electromechanical equipment.
Building a High Channel Density Digital IO Module for the Next Generation Industrial Automation Controller
There are currently many articles introducing Industry 4.0, and smart sensors are becoming increasingly popular in factory environments (I and other authors have written about these topics). Although we have all noticed a significant increase in the use of sensors in factories, processing plants, and even some newly built automation systems, the widespread use of sensors has also brought about an important change, which is the need to handle a large amount of IO within these old controllers. These IOs may be digital or analog. This requires the construction of high-density IO modules with size and heat limitations. In this article, I will focus on digital IO, and in subsequent articles, I will introduce analog IO.
Usually, digital IO in PLC consists of discrete devices such as resistors/capacitors or independent FET drives. In order to minimize the size of the controller as much as possible and to handle 2 to 4 times the number of channels, this has led to a shift from a separate approach to an integrated approach.
We can use the entire article to illustrate the drawbacks of the split method, especially when the number of channels processed by each module reaches 8 or more. However, when it comes to high heat/power consumption, a large number of split components (from the perspective of size and mean time between failures (MTBF)), and the need for reliable system specifications, it is sufficient to demonstrate that the split method is not feasible.
Figure 1 shows the technical challenges faced in building high-density digital input (DI) and digital output (DO) modules. In both Di and DO systems, size and heat dissipation issues need to be considered.
Digital input
size
heat
Supports all input types
Type 1, 2, 3, Input
Supports 24 V and 48 V inputs
Robust operating specifications
Wire breakage detection
Digital output
Support for different types of output driver configurations
size
Integrated demagnetization of inductive loads
Heat – When driving multiple outputs
Drive accuracy
diagnosis
For digital input, it is also important to note that it supports different input types, including 1/2/3 type inputs, and in some cases, 24V and 48V inputs. In all cases, reliable operating characteristics are crucial, and sometimes circuit detection is also crucial.
For digital outputs, the system uses different FET configurations to drive the load. The accuracy of the driving current is usually an important consideration. In many cases, diagnosis is also very important.
We will explore how integrated solutions can help address some of these challenges.
Design a High Channel Density Digital Input Module
The traditional split design uses a resistive voltage divider network to convert 24V/48V signals into signals that can be used by microcontrollers. The front-end can also use discrete RC filters. If isolation is required, external optocouplers are sometimes used.
Figure 1 shows a typical discrete method for constructing digital input circuits.
Figure 1. Considerations for digital input and output modules.
This type of design is suitable for a certain number of digital inputs; 4 to 8 per board. Beyond this number, this design will soon become impractical. This separation scheme can bring various problems, including:
High power consumption and related board high temperature points.
Each channel requires an optocoupler.
Excessive components can lead to low FIT rate and even require larger devices.
More importantly, the split design method means that the input current increases linearly with the input voltage. Assuming a 2.2K Ω input resistor and 24V V is used. When the input is 1, for example, at 24V, the input current is 11mA, which is equivalent to a power consumption of 264mW. The power consumption of the 8-channel module is greater than 2W, and the power consumption of the 32-bit module is greater than 8W. Refer to Figure 3 below
From a cooling perspective alone, this split design cannot support multiple channels on a single board.
One of the biggest advantages of integrated digital input design is the significant reduction in power consumption, thereby reducing heat dissipation. Most integrated digital input devices allow configurable input current limitations to significantly reduce power consumption.
When the current limiting value is set to 2.6mA, the power consumption is significantly reduced, with each channel approximately 60mW. The rated value of the 8-channel digital input module can now be set below 0.5
Another reason for opposing the use of split logic design is that sometimes DI modules must support different types of inputs. The standard 24V digital input specifications published by IEC are divided into Type 1, Type 2, and Type 3. Type 1 and Type 3 are usually used in combination because their current and threshold limits are very similar. Type 2 has a current limit of 6mA, which is higher. When using the split method, it may be necessary to redesign as most discrete values need to be updated.
However, integrated digital input products typically support all three types. Essentially, Type 1 and Type 3 are generally supported by integrated digital input devices. However, in order to meet the minimum current requirement of 6mA for Type 2 input, we need to use two channels in parallel for one field input. And only adjust the current limiting resistance. This requires a circuit board change, but the change is minimal.
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