I recently received a unique request from a customer regarding a project. I have successfully written and tested the logic using just 7 outputs and inputs on one PLC. I am sharing the details along with screenshots in case anyone is interested in trying it out as a new project. While working on this, I made sure to thoroughly test the logic to ensure it runs smoothly without any issues. Despite the project not being a major undertaking for me, I am hesitant to continue working with this particular customer due to their preference for cost-saving measures. I have put the processor through rigorous testing and it has proven to work effectively. The timers have been optimized to prevent overloading an I/O card, with the maximum update time being around 25 seconds. I welcome any feedback or thoughts on this project.
Rayman_7676 requested feedback on a parallel port driver they had written. Share your thoughts below! It's often said that working with zeros and ones is not as difficult as it may seem - a belief echoed by Jouni Rynö.
I have a deep passion for this type of hardware hacking. Back in 1984, during my 8th grade science project, I used a combination of TTL chips, LEDs, and salvaged fiber optic cables to create a project similar to this one. While my project was not as fast as modern technology, I had no guidance on parallel ports and clock pulses. In a rural area in Ontario, I successfully implemented a bit-shift register between a PLC-5 and a MicroLogix 1000 by using a single 120V AC input to load a preset into a high-speed counter. However, I am concerned about potential risks with the I/O update occurring during a routine. I have yet to open and import the data to fully understand your process.
Drbitboy - In the past, I dabbled with serial communication for basic tasks like passing alarm numbers. However, I knew there had to be a better way. After thinking about it before going to bed last night, I had some free time today and managed to make it work. I made countless mistakes along the way, but that's what testing is for, right? Thanks to Ken's help! Unfortunately, I didn't have the opportunity to learn these skills when I was younger; I was always expected to do manual labor. However, I always had an interest and finally decided to step up and learn something new. It's never too late to learn new things! I considered using a shift register but ultimately chose a different approach. Time-based logic can be tricky, but for this non-critical task of updating an alarm string with around 30 characters, a 5-second update time should suffice. I didn't have the necessary I/O cards or two PLCs to work with, but I was able to prove the concept. Hopefully, I'll have the chance to test it in the office soon. The suggestion about I/O updates was spot on.
In the distant past, I have successfully implemented a few projects using handshaking bits instead of timers for efficient communication. By utilizing 7 bits for characters and allocating one bit for each direction for handshaking, I was able to achieve a fast and reliable transmission. In another project, I utilized relay outputs with a PLC, which proved to be durable and lasted for at least 3 years. I did not revisit the project after that timeframe.
Oh, I see what you're saying - I understand that this is the requested method. I'm just trying to figure out what to do with the remaining 8 bits in ASCII, which conveniently fits within 128. I can't just leave one hanging, right? In the past, I would assign decimal values for the first 7 alarms, but then you're limited to only 127 alarms and you should never use 0 as an alarm number. The last bit could be used as a confirmation/done bit. However, with ASCII, you have the flexibility to assign any value to the alarm number. How should we utilize the last bit effectively?
That sounds like a very efficient approach you've taken there, especially making sure the logic runs smoothly and mitigating the risk of overloading an I/O card with your smart timer optimization. This just goes to show how we can deliver great solutions even under budget constraints. But as you've mentioned, it's essential to ensure that cost-saving measures don't compromise the quality or increase the risk of future failure. Your hesitation to further deal with this client hints towards them potentially not valuing your expertise or understanding the importance of quality over mere cost-saving. Sounds like a conversation is due with the client around these points. Thanks for sharing your project details! I'll definitely take note of this.
Thanks for sharing this, your approach to optimize the use of I/O on a single PLC is instructive. It's interesting that you've achieved success with just 7 outputs and inputs. As for your concern with the customer's cost-saving measures, it is indeed a common challenge many of us face. I hope they appreciate the hard work and precision you've put into this project. The dedication to thorough testing and preventing I/O overload shows your commitment to delivering quality work which should be valued. Technically, a 25 seconds update time sounds pretty decent for the setup you've described. Keep up the great work!
Really appreciate you sharing your project here, the concept of optimizing timers to prevent overloading sounds quite efficient. I can understand your concerns about working with a cost-focused client. While it can be a challenge, it can also be seen as an opportunity to innovate without sacrificing the quality of your work. Just remember to value your expertise and effort properly. Would love to see more details or maybe step-by-step of your innovative logic process though, especially on how you managed with just 7 I/Os. Thanks again for the insights!
It sounds like you've done an impressive job optimizing that PLC project, especially with the testing you've put into it! I can understand your hesitation about continuing with a customer focused on cutting costs—it's tough to balance quality and budget constraints. Maybe consider outlining the long-term benefits of your solution to help them see the value in what you're providing. I'd love to take a look at your screenshots; sharing your logic could really inspire others in our community!
It's great to hear about your success with the PLC project! It sounds like you've really put in the effort to ensure everything runs smoothly, which is impressive. I completely understand your hesitation with the customer—sometimes, prioritizing cost can lead to compromises on quality and support. Have you considered discussing your concerns with them to see if you can reach a better understanding or maybe even adjust the project scope? It might be worth trying to find a balance that works for both sides. Also, I'm definitely interested in your screenshots; they could provide some valuable insights for my own work!
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Answer: - The unique request from the customer was to send an 80 character string between PLCs using RSLogix5000, with the project being implemented with just 7 inputs and outputs on one PLC.
Answer: - The logic was thoroughly tested to ensure smooth operation without any issues. The processor underwent rigorous testing, and the timers were optimized to prevent overloading an I/O card, with a maximum update time of around 25 seconds.
Answer: - Despite the project not being a major undertaking, the challenge of working with a customer preferring cost-saving measures was mentioned. However, the project was successfully executed with efficient logic and optimized timers to meet the requirements.
Answer: - Yes, the details and screenshots of the project have been shared in the discussion thread for anyone interested in trying it out as a new project. Feel free to review the content and provide feedback or thoughts on the project.
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