Modular Software Configurable IO PLC

Modular_Software_Configurable_IO_PLC

Overview

This repository contains a modular KiCad design project for a Software Configurable I/O PLC. The project integrates several advanced components to create a versatile and powerful industrial control solution. It features software-configurable analog and digital I/O, single-pair Ethernet with Power over Data Line (PoDL) capabilities, and a robust power architecture.

Disclaimer

[!NOTE] This project is provided "as is" and without any warranty, express or implied. For more details, please see the LICENSE file.

About the Key Components

This PLC design is built around a combination of high-performance integrated circuits:

• Analog Devices AD74413R: A quad-channel, software-configurable I/O solution that can be configured on a per-channel basis for analog input/output, digital input/output, and resistance temperature detector (RTD) measurements.
• Analog Devices ADIN1110: A low-power, single-port 10BASE-T1L MAC-PHY, enabling Ethernet connectivity over a single twisted pair of cables (Single-Pair Ethernet), ideal for long-distance communication in industrial environments.
• Analog Devices LT8304: A micropower, no-opto isolated flyback converter, providing a simple and efficient solution for isolated power supplies.
• Analog Devices LTC9111: An IEEE 802.3cg/802.3bt Power over Data Lines (PoDL) Power Sourcing Equipment (PSE) controller, allowing the PLC to power connected devices over the same data cable.
• Maxim Integrated MAX14906: A quad-channel, high-speed, high-side switch and digital output driver, offering robust and protected digital outputs.

Project Structure

modular_software_configurable_io_plc/
├── modular_software_configurable_io_plc.kicad_pro    # Project configuration file
├── modular_software_configurable_io_plc.kicad_sch    # Main schematic file
├── modular_software_configurable_io_plc.kicad_pcb    # PCB layout file
├── fp-lib-table                                      # Footprint library table
├── sym-lib-table                                     # Symbol library table
├── docs/                                             # Documentation files
│   ├── bom/                                          # Bill of Materials
│   │   └── modular_software_configurable_io_plc_ibom.html # Interactive BOM file
│   ├── pictures/                                     # Images and photos
│   │   ├── 1_modular_software_configurable_io_plc_side.png
│   │   ├── 2_modular_software_configurable_io_plc_top.png
│   │   ├── 3_modular_software_configurable_io_plc_bottom.png
│   │   ├── 4_modular_software_configurable_io_plc_left.png
│   │   ├── 5_modular_software_configurable_io_plc_right.png
│   │   ├── 6_modular_software_configurable_io_plc_front.png
│   │   ├── 7_modular_software_configurable_io_plc_back.png
│   │   ├── 8_modular_software_configurable_io_plc_side_exploded_1.png
│   │   ├── 9_modular_software_configurable_io_plc_side_exploded_2.png
│   │   ├── 10_modular_software_configurable_io_plc_side_exploded_3.png
│   │   ├── 11_modular_software_configurable_io_plc_side_enclosure.png
│   │   ├── 12_modular_software_configurable_io_plc_top_enclosure.png
│   │   ├── 13_modular_software_configurable_io_plc_bottom_enclosure.png
│   │   ├── 14_modular_software_configurable_io_plc_left_enclosure.png

Project Features

This design provides a comprehensive and modular software-configurable I/O PLC with:

• Modular Architecture: Incorporates several minimal functional modules for scalability and ease of design.
• Software-Configurable I/O: Flexible channels that can be adapted to various sensor and actuator types.
• Single-Pair Ethernet (SPE): Utilizes 10BASE-T1L technology for long-reach Ethernet communication.
• Power over Data Line (PoDL): Capable of providing power to remote devices over the data line, simplifying wiring.
• Isolated Power: Features an isolated power supply for improved safety and noise immunity.
• High-Side Digital Outputs: Robust and protected digital outputs suitable for industrial loads.

Getting Started

Prerequisites

• KiCad EDA version 9.0 or later installed on your system.
• Git for cloning the repository and managing submodules.

Opening the Project

1. Clone the repository (including submodules):

   git clone --recursive https://github.com/ionutms/Modular_Software_Configurable_IO_PLC.git

   If you have already cloned the repository without submodules, initialize them with:

   git submodule init
   git submodule update

2. Open the project in KiCad:

   • Launch KiCad.
   • Click "Open Existing Project".
   • Navigate to the cloned repository folder.
   • Select the modular_software_configurable_io_plc.kicad_pro file.

3. Explore the design:

   • Open the schematic editor to view the circuit design.
   • Open the PCB editor to view the board layout.

Dependencies

This project has the following dependencies:

1. KiCAD Symbols Generator

This repository uses KiCAD_Symbols_Generator as a submodule for custom symbol generation.

To initialize the submodule after cloning this repository:

git submodule update --init --recursive

2. 3D Models

This project requires the 3D_Models_Vault repository for 3D models.

Setup for KiCAD 9:

1. Clone the 3D models repository:

   git clone https://github.com/ionutms/3D_Models_Vault.git

2. In KiCad 9, add an environment variable:

   • Go to Preferences -> Configure Paths...
   • Click Add to create a new environment variable.
   • Variable Name: KICAD9_3D_MODELS_VAULT
   • Variable Path: The full, absolute path to where you cloned the 3D_Models_Vault repository.

Symbol Generator Submodule

This project includes the KiCAD_Symbols_Generator as a submodule, which provides tools for generating KiCad symbols from CSV data files. For more information on using this tool, see the documentation within the submodule's directory.

Documentation

The docs folder contains:

• Schematic PDF exports.
• An interactive Bill of Materials (BOM).
• Images and renderings of the PCB and enclosure.

Visuals

The following images showcase the PCB design from different perspectives:

PCB Views

Top View of the PCB

Side View of the PCB

Bottom View of the PCB

Left View of the PCB

Right View of the PCB

Front View of the PCB

Back View of the PCB

Exploded Views

Side Exploded View 1

Side Exploded View 2

Side Exploded View 3

Enclosure Views

Side View with Enclosure

Top View with Enclosure

Bottom View with Enclosure

Left View with Enclosure

Right View with Enclosure

Front View with Enclosure

Back View with Enclosure

License

This project is licensed under the MIT License - see the LICENSE file for details.

References

• AD74413R Datasheet
• ADIN1110 Datasheet
• LT8304 Datasheet
• LTC9111 Datasheet
• MAX14906 Datasheet
• KiCad EDA