Power Distribution Unit (PDU) Safety Logic Redesign
Laine, Michael (2023)
2023
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2023052514264
https://urn.fi/URN:NBN:fi:amk-2023052514264
Tiivistelmä
The project’s goal was to find new Programmable Logic Controllers and implement them in the existing Power Distribution Unit design. The PDU was to be integrated into present, and next functional test stations. The PLC’s safety logic was redesigned and integrated with an external monitoring application using the Modbus TCP communication protocol.
The project began with researching safety PLC modules and integrating them into the PDU design. This was followed by safety logic programming, PDU assembly, and PLC testing. The final step was the integration of the PLC into an external monitoring application and debugging of the PDU in an FCT test station.
ReeR Safety PLC devices were selected as part of the project. They consisted of the main safety module MOSAIC M1SC COM, input module MI16L and output module MO4LC. The set provided 24 V logic signal levels and Modbus communication. In addition, a combination of signals was supplied to meet the PDU system requirements, which included 22 inputs, 5 outputs, 4 clocks, and 4 monitoring signals. The redesign was implemented within assembly documentation and was accomplished by building two PDU units. Also, the safety logic was upgraded and tested in a special test bench setup. Remote access via Modbus protocol was also enabled and the data stream from the units was integrated into an external application. Finally, the PDU units were thoroughly tested in the FCT test stations.
Apart from minor alterations in PDU's internal circuitry, the project was deemed successful. It provided a new PDU revision that will be used in the next FCT stations as well as in the platforms currently in use.
However, further research and subsequent selection of the safety PLC are recommended. The initial definition of their characteristics could be improved, and their use in the whole system, including its subsystems, could be re-studied. Alternatively, a fully new design based on available safety devices could prove beneficial over adaptations within soon obsolete solutions.
The project began with researching safety PLC modules and integrating them into the PDU design. This was followed by safety logic programming, PDU assembly, and PLC testing. The final step was the integration of the PLC into an external monitoring application and debugging of the PDU in an FCT test station.
ReeR Safety PLC devices were selected as part of the project. They consisted of the main safety module MOSAIC M1SC COM, input module MI16L and output module MO4LC. The set provided 24 V logic signal levels and Modbus communication. In addition, a combination of signals was supplied to meet the PDU system requirements, which included 22 inputs, 5 outputs, 4 clocks, and 4 monitoring signals. The redesign was implemented within assembly documentation and was accomplished by building two PDU units. Also, the safety logic was upgraded and tested in a special test bench setup. Remote access via Modbus protocol was also enabled and the data stream from the units was integrated into an external application. Finally, the PDU units were thoroughly tested in the FCT test stations.
Apart from minor alterations in PDU's internal circuitry, the project was deemed successful. It provided a new PDU revision that will be used in the next FCT stations as well as in the platforms currently in use.
However, further research and subsequent selection of the safety PLC are recommended. The initial definition of their characteristics could be improved, and their use in the whole system, including its subsystems, could be re-studied. Alternatively, a fully new design based on available safety devices could prove beneficial over adaptations within soon obsolete solutions.