Single Rack Architecture

PLCCreator

Single Rack Architecture

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1. Introduction
2. Use Cases
3. Creating a Single Rack PLC
4. Rack Type Configuration
5. Flexible Architecture Conversion
6. IO Lists
7. Examples

1.
Introduction

PLCCreator enables you to build PLC systems using 3 distinct architectural models:

  1. Single Rack
  2. Single Fieldbus
  3. Multiple Fieldbuses

The Single Rack model provides a compact solution where all components reside in one rack:

  • CPU and IO modules
  • All signal connections contained within the rack
  • Ideal for simpler applications
Figure 1: Principal Structure of the Single Rack Architecture

2.
Use Cases

The Single Rack Architecture is ideal for applications where simplicity and compactness are key:

Compact Machinery

Perfect for standalone machines where all IO points can be centralized in one control cabinet.

Small to Medium Processes

Ideal for contained processes with limited IO requirements that don't need distributed control.

And any other applications where all IO signals are connected within a single cabinet.

3.
Creating a Single Rack PLC

Prerequisites

To create a Single Rack PLC:

  1. Prepare either a Signal IO List , or a Device IO List
  2. Follow the Create PLC with PLCCreator guide
  3. Make sure you select "Single Rack Architecture" on the PLC Architecture page

The remaining process is automated as described below.

Generation Process

When you click "Generate" on the Generate page, PLCCreator generates PLC hardware configuration using the algorithm for a signal IO List processing , or a device IO List processing

By adhering to common automation conventions, IO modules in the PLC rack are organized in the following order:

  1. DI - Digital Input Modules
  2. DO - Digital Output Modules
  3. AI - Analog Input Modules
  4. AO - Analog Output Modules
Figure 2: Typical Hardware Configuration of the PLC with Single Rack Architecture

4.
Rack Type Configuration

Before generating your PLC on the Generate page, you must set the rack type:

Figure 3: Rack Type Setting for Single Rack Architecture on the "Generate" page
Figure 3: Rack Type Setting for Single Rack Architecture on the "Generate" page

Choose between:

Standard Rack

  • Default selection
  • CPU and IO modules in single rack
  • Lower hardware cost
Figure 1

Standalone CPU

  • CPU in separate rack without IO
  • IO modules in expansion rack(s)
  • Better scalability, reliability and operational efficiency
Figure 4
Figure 4: Principal Structure of PLC with Standalone CPU and its Expansion Rack
Figure 4: Principal Structure of PLC with Standalone CPU and its Expansion Rack

5.
Flexible Architecture Conversion

If single rack is not ehough for your application, the system seamlessly converts your configuration to a Single Fieldbus Architecture

PLCCreator creates additional racks and configures required fieldbus components automatically.

Figure 5: Principal Structure of the Single Fieldbus Architecture
Figure 5: Principal Structure of the Single Fieldbus Architecture

Automatic Conversion Triggers

During generation, PLCCreator monitors many parameters and converts to fieldbus architecture when triggered by:

IO Capacity Limit

When exceeding rack hardware limits:

  • Number of modules
  • Communication capacity
  • Power capacity

Rack Size Parameters

When exceeding your limits set on the Rack Size page:

  • Module Count
  • Width
  • Power

Key Advantage

This intelligent conversion allows you to:

  • Confidently begin with simple single-rack designs
  • The system adapts automatically

7.
Examples

You can find following examples for Single Rack Architecture on My PLCs page: