Some time ago, during the commissioning of a project, I encountered serious communication issues with an industrial Ethernet network using a star topology. The data transmission speed between sub-stations in the local area was extremely slow, and even the communication between the upper-level system and the local stations was not reliable. In some cases, critical control functions couldn’t be executed at all. It was clear that there was a major network problem that needed to be addressed immediately.
After extensive analysis and testing, I finally managed to resolve the issue through three key improvements. I want to share my experience here so others can benefit from it as well.
1) I upgraded the local PLC to use the Momentum series modules and switched the programming environment to Concept 2.6. Instead of using the original Read_Reg function block for data exchange, I replaced it with CRead_Reg, which allows the module to automatically read the required data continuously. This significantly improved the efficiency of data retrieval.
2) Previously, all sub-stations were treated equally, with both A and B stations reading from each other. This created a bottleneck in the network and often led to communication delays. After the improvement, one station was designated as the main controller, responsible for initiating read/write operations. It would request the necessary data from the other station and also send the data that the other station needed. This reduced unnecessary traffic and improved overall performance.
3) I optimized the data transmission part of the original program by replacing multiple individual read/write function blocks with a single continuous read/write operation for multiple registers. This made the communication more efficient and less resource-intensive, further enhancing the stability of the network.
By implementing these changes, the network communication issues were successfully resolved. The system now runs smoothly, with fast and reliable data exchange between all stations. This experience taught me the importance of optimizing both the hardware configuration and the software logic when dealing with complex industrial networks. I hope this sharing helps others facing similar challenges in their projects.
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