Quick change flash memory on a PLC for universal application

[adamb]

I have what we call a universal equipment configuration as follows. We have a tooling top with a number of sensors that need to go through a specific sequence. Our market neiche was to develop a base unit that contains the controls, air valves, etc. to operate a multitude of these tooling tops. The problem is, the plc program becomes huge due to the fact I have to incorporate every top that is going to run on the base. I cannot approach this with a "recipe" style set up due to the diversity of the tooling configurations, and sequence of operation. I am trying to find a PLC with quick change memory so that you can store the memory with the tooling top and plug it in when you are going to run it. This way the program is gauranteed to work properly every time, and on any base unit that I have in the field. I want this to work like an old gaming system, plug in the cartridge, and away we go. This will also solve my integration issues new tops for base units that are located in other countries. Currently I am using an omron CJ1-CPU11 with expansion modules, but am open to any new brands that may have better memory card options. Thanks.

[TConnolly]

What is your complaint, if any, about the Omron PLC? Your request is interesting, because it seems that you want to cut down on program code management issues with a single plug and play solution. Omron's PLCs are as good as or better than most (although its not my personal favorite) But if you go and start offering another PLC then you have just doubled your software management requirements and significantly raised the software development costs. Thats why I'm wondering if there is something you don't like about the Omron.

[Crossbow]

I think the question he's asking doesn't say he doesn't like the PLC, he's just unsure of the memory module capabilites of the CJ1. Many PLCs offer memory cards which can store programs, data, and such. I don't personally know the CJ1, but I know the Mitsubishi FX3U has the ability to store data registers and PLC program to a memory cassette which can be easily switched out.

[adamb]

No complaints about omron. I am happy with the product. Omron tech support said they have no PLC's capable of what I am requesting, so I was curious if any other products offered what I desired. Thanks for the reply.

[adamb]

I will look into the Mitsubishi, "easily switched out" is exactly what I am looking for. Thanks for the reply

[gravitar]

I'm surprised Omron told you they didn't have a means of accomplishing this. I would have assumed all the major name PLC brands would have a non-volatile memory capability on at least one of their product lines. Maybe they didn't understand your question? Allen-Bradley would be another brand to consider, as this can easily be done with the SLC 500, micrologix (not the 1000 though), and I'm sure the ControlLogix family is fully capable of this as well, although I can'd speak to that from personal experience.

[TConnolly]

The CompactLogix family has models that can use a standard flash card, like the one you would use in your camera. This is about as close as you can get to "game console" functionality. The Micrologix family (all except the ML1000) uses an EEPROM module that plugs in under a cover on the front of the PLC. The ControlLogix PLCs have an EEPROM socket that you can access when the card is out of the rack. Edited September 26, 2007 by Alaric

[Clay B.]

You may have already thought of this but why not take it from a subroutine approch. Each tool program is its own subroutine. The subroutine is activated by a selector switch, thumbwheel, numeric input...etc. this also makes management easier. Whenever a new tool is created you just have to add a subroutine. Since each tool program is its own subroutine troubleshooting is made alot easier also.

[Crossbow]

As for the AB SLC or ControlLogix, that's not really a comparable device to the CJ1. The CJ1 is a low cost PLC, not a big rack-based system. I don't know if Omron has the ability to store the data registers to the memory cards. I think that might be the issue with theirs, I think the card only stores the program.

[TConnolly]

According to the manual I linked, it can do program, data, or both. Power has to be cycled to cause it to reload the program (which is typical)

[Sleepy Wombat]

Who ever is your Omron rep should really study a bit more about their own products. Yes- Omron can store the program and all data into a plugin COMPACT FLASH card. Have done it ... especiallly for program mods where there is no modem access avail. just send the compact flash card. Don;t even need a PLC at this end only a compact flash card reader/writer... BTW a standard out of the box 256MB compact flash will work. Crossbow mate, never assume.....