A control method and product for an integrated PLC controller supporting multiple interfaces and multiple communication protocols.

Abstract

The application provides a control method and product of an integrated PLC controller supporting multiple interfaces and multiple communication protocols, and belongs to the technical field of PLC controllers.The method comprises the following steps: the PLC controller automatically identifies the interface type and communication protocol of a connected device through a built-in multi-interface adapter; the PLC controller configures the communication protocol according to the identification result, wherein the configuration comprises setting communication parameters and data formats; and the PLC controller collects the running data of the connected device in real time through the configured communication protocol, processes the collected running data, and obtains a processing result.Through automatic identification of the interface type and communication protocol of the connected device, the PLC controller can quickly adapt to various devices and systems, reduces the workload and misconfiguration risk of manual configuration, and improves the efficiency and flexibility of system integration.

Description

Technical Field

[0001] This invention proposes a control method and product for an integrated PLC controller that supports multiple interfaces and multiple communication protocols, belonging to the field of PLC controller technology. Background Technology

[0002] In the field of industrial automation, programmable logic controllers (PLCs) play a crucial role. They are widely used in various industrial control systems to achieve functions such as real-time monitoring, data acquisition, logic control, and fault alarms for production equipment. However, with the diversification and complexity of industrial equipment, traditional PLC controllers face many challenges, such as the diversity of interface types, the compatibility of communication protocols, the real-time nature of data acquisition, and the flexibility of control strategies.

[0003] Traditional PLC controllers often only support a limited number of interface types and communication protocols. This necessitates cumbersome interface adaptation and communication protocol conversion when connecting devices from different manufacturers and models, significantly increasing system complexity and maintenance costs. Furthermore, traditional PLC controllers have limited data acquisition and processing capabilities, making it difficult to meet the high precision and efficiency demands of modern industrial production. Simultaneously, with the development of the Industrial Internet, the requirements for the networking and collaborative capabilities of PLC controllers are becoming increasingly stringent. Summary of the Invention

[0004] This invention provides a control method and product for an integrated PLC controller that supports multiple interfaces and multiple communication protocols, in order to solve the problems mentioned in the background art above:

[0005] This invention proposes a control method for an integrated PLC controller that supports multiple interfaces and multiple communication protocols. The method includes:

[0006] S1, the PLC controller automatically identifies the interface type and communication protocol of the connected device through its built-in multi-interface adapter;

[0007] S2. Based on the identification results, the PLC controller configures the communication protocol, including setting communication parameters and data format;

[0008] The S3 and PLC controllers collect real-time operating data from connected devices through the configured communication protocol, process the collected operating data, and obtain the processing results.

[0009] S4. Based on the obtained processing results and preset control logic, the PLC controller controls the connected devices and performs coordinated control of the connected devices by networking with other PLC controllers.

[0010] S5. During the control process, the operating status of the equipment is monitored in real time through the fault diagnosis module of the PLC controller. If an abnormality is detected, the PLC controller will immediately trigger the alarm mechanism and send the fault information to relevant personnel through multiple communication interfaces.

[0011] Furthermore, S1 includes:

[0012] S11. Start the PLC controller, execute the initialization program, activate the built-in multi-interface adapter, scan the available physical interfaces through the adapter, and generate an interface list;

[0013] S12. The adapter sends a general probe signal to each interface and waits for the response from the connected device. Upon receiving the response signal, the adapter analyzes the characteristics of the response signal and preliminarily identifies the interface type by comparing it with a preset interface type feature library.

[0014] S13. If the initial identification fails, the adapter sends a probe signal again to obtain interface information. Based on the obtained interface information, the adapter compares the interface type feature library again to determine the interface type.

[0015] S14. Based on the determined interface type, the adapter further sends a protocol probe packet. The adapter analyzes the response packet returned by the device, checks the matching degree of specific identifiers, and classifies the protocols using a protocol feature library and machine learning algorithms.

[0016] S15. If the protocol identification result is still uncertain, the adapter will initiate multiple rounds of interactive verification, which will enhance the identification accuracy by sending probe signals and receiving feedback multiple times; and return the determined interface type and communication protocol to the main program of the PLC controller.

[0017] Furthermore, S2 includes:

[0018] S21. After receiving the interface type and communication protocol identification results returned by the adapter, the PLC controller retrieves the corresponding communication protocol configuration template from the internal database.

[0019] S22, the PLC controller searches the retrieved configuration template, extracts the parameters required for the communication protocol, and adjusts the parameters according to actual needs through the communication parameter configuration options provided by the user interface;

[0020] S23. The PLC controller generates a communication parameter list based on the configuration template and the adjusted parameters, and stores the communication parameter list in an internal register.

[0021] S24. The PLC controller initializes the corresponding physical interface according to the interface type, sets the physical layer parameters of the interface, and loads the corresponding protocol stack and library files for the application layer protocol.

[0022] S25. After configuration, the PLC controller initiates a connection test, sends a test data packet to the connected device, and waits for a response. The PLC controller analyzes the test response to verify the stability of the communication link and the integrity of the data.

[0023] S26. If the test fails, the PLC controller will record the error message and reconfigure or provide an error message.

[0024] Furthermore, S22 includes:

[0025] The PLC controller extracts the basic parameters required for the communication protocol from the retrieved configuration template. These basic parameters include baud rate, data bits, stop bits, and parity method.

[0026] The PLC controller performs initial configuration of the extracted parameters, selecting electrical parameters and signal processing methods based on the interface type; the PLC controller provides communication parameter configuration options through the user interface, allowing users to fine-tune the parameters as needed;

[0027] After the parameter configuration is completed, the PLC controller performs parameter verification and conflict detection. If there is a parameter conflict or configuration error, the controller will provide an error message and solution, and the user can make corrections according to the error message and solution.

[0028] During operation, the PLC controller monitors the real-time operating status and communication quality of the equipment, and dynamically adjusts communication parameters based on the operating status and communication quality.

[0029] Furthermore, during operation, the PLC controller monitors the real-time operating status and communication quality of the device, and dynamically adjusts communication parameters based on the operating status and communication quality, including:

[0030] The PLC controller acquires real-time operating status data of connected devices through built-in sensors and interface circuits, and monitors communication quality through the communication link.

[0031] The PLC controller stores the acquired operating status and communication quality data in a database, performs historical data analysis and trend prediction through a built-in trend prediction model, and conducts big data analysis to identify potential problems with the equipment and bottlenecks in the communication link.

[0032] Based on the trend prediction model, the communication demand in the future period is predicted;

[0033] Based on the results of status monitoring and communication quality assessment, a dynamic parameter adjustment strategy is developed;

[0034] Based on the established adjustment strategy, communication parameters such as baud rate, data bits, and stop bits are adjusted in real time. After the parameters are adjusted, the PLC controller re-evaluates the communication quality and verifies the adjustment effect.

[0035] If the verification passes, continue monitoring; if the verification fails, revise and adjust the strategy based on the new evaluation results.

[0036] The PLC controller records the results of each parameter adjustment and the changes in communication quality. Based on an adaptive learning algorithm, the controller continuously optimizes the parameter adjustment strategy.

[0037] Furthermore, S3 includes:

[0038] S31: The PLC controller constructs a data request frame according to the configured communication protocol, and sends the constructed data request frame to the connected device through the initialized communication interface.

[0039] S32. The connecting device receives the request frame, processes the request according to the communication protocol requirements, and generates a response frame containing running data.

[0040] The S33 PLC controller receives the response frame, parses the response frame using the loaded protocol stack and decoder in the library file, processes the parsed data, and obtains the processed result.

[0041] Furthermore, S4 includes:

[0042] S41, the PLC controller generates a sequence of control instructions based on the processing results and the preset control strategy, and encodes and formats the sequence of control instructions to obtain a control frame under a specific communication protocol;

[0043] S42. The PLC controller transmits control frames to the connected device through the communication interface. After receiving the control frames, the connected device executes corresponding actions or adjusts parameters.

[0044] S43. During execution, the PLC controller coordinates with other PLC controllers, exchanges information and synchronizes instructions through the network, and assigns tasks according to equipment status, priority and preset rules.

[0045] Furthermore, S43 includes:

[0046] PLC controllers are connected via a network based on a communication protocol; each PLC controller is assigned a unique identifier or address in the network.

[0047] When the PLC controller starts up, it automatically performs network detection, uses the network to exchange information in real time with other PLC controllers, and synchronizes information based on timestamps.

[0048] Each PLC controller monitors the status of the equipment under its control. The PLC controller evaluates the priority of the equipment based on the real-time status, historical data and preset rules.

[0049] Based on equipment status, priority, and preset rules, and using a distributed decision-making algorithm, PLC controllers collaborate to determine the tasks to be executed and their priorities.

[0050] During the task allocation process, the resource utilization of each PLC controller is monitored in real time through the resource manager, and dynamic adjustments are made through the load balancing algorithm.

[0051] Based on the results of collaborative decision-making, each PLC controller generates corresponding control instructions.

[0052] In the process of coordinated control, if a conflict occurs, the controller will resolve the conflict by detecting command conflicts and resource competition in the network and using an arbitration mechanism.

[0053] The PLC controller continuously collects data during the collaborative control process. The controller uses the data from the mobile phone and performs self-learning based on deep learning algorithms to continuously optimize the collaborative decision-making and task allocation algorithms.

[0054] Furthermore, S5 includes:

[0055] The fault diagnosis module of the S51 PLC controller receives status information and operating data from the connected device in real time. Through pattern recognition and machine learning algorithms, it performs real-time analysis and prediction of status information based on the built-in fault diagnosis model to identify potential faults or anomalies.

[0056] S52. If an abnormal situation is detected, the fault diagnosis module will immediately trigger the alarm mechanism. For serious faults, the fault diagnosis module will immediately trigger emergency shutdown or protection measures.

[0057] S53. At the same time, the PLC controller records the fault information and stores it in the internal memory or external database.

[0058] S54. The fault diagnosis module performs in-depth analysis and diagnosis of fault information through the built-in fault analysis model. Based on the results of in-depth analysis and diagnosis, it determines the cause of the fault and generates a solution.

[0059] S55. The cause of the fault and the solution are sent to relevant personnel through various communication methods. After receiving the cause of the fault and the solution, the relevant personnel take appropriate action.

[0060] The present invention proposes a computer program product, including a computer program / instruction, which, when executed by a processor, implements a control method for an integrated PLC controller supporting multiple interfaces and multiple communication protocols as described above.

[0061] The beneficial effects of this invention are as follows: By automatically identifying the interface type and communication protocol of connected devices, the PLC controller can quickly adapt to various devices and systems, reducing the workload of manual configuration and the risk of misconfiguration, and improving the efficiency and flexibility of system integration. The function of dynamically adjusting communication parameters ensures optimal communication performance under different operating conditions and communication environments, improving the stability and reliability of data transmission. The real-time monitoring and early warning capabilities of the fault diagnosis module further ensure the continuous and stable operation of the system. Combined with preset control logic and real-time data processing, the PLC controller can accurately control connected devices, achieving efficient automation. Through collaborative control and task allocation with other PLC controllers, not only is resource utilization optimized, but the overall system response speed and processing capacity are also improved, making it particularly suitable for large-scale industrial automation scenarios. The real-time monitoring and predictive analysis capabilities of the fault diagnosis module enable the system to take preventive measures before faults occur, effectively reducing unplanned downtime. Once a fault is detected, the immediately triggered alarm mechanism and fault handling process can respond quickly, reducing losses. Through adaptive learning algorithms and deep learning, the PLC controller continuously optimizes communication parameter adjustment strategies and collaborative control algorithms, achieving an improvement in the level of intelligence. This self-optimization capability enables the system to better adapt to new equipment, new communication standards, and complex operational needs that may arise in the future. The highly integrated design and intelligent fault handling processes simplify system maintenance and reduce reliance on specialized technical personnel. Meanwhile, modular communication protocol support and dynamic configuration capabilities make system upgrades more convenient, facilitating long-term technological iteration and functional expansion. Attached Figure Description

[0062] Figure 1 This is a diagram illustrating the steps of the method described in this invention. Detailed Implementation

[0063] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0064] Numerous specific details are set forth in the following description to provide a thorough understanding of the invention. The described embodiments are only a part of, and not all, of the embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0065] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0066] One embodiment of the present invention provides a control method for an integrated PLC controller supporting multiple interfaces and multiple communication protocols, the method comprising:

[0067] S1, the PLC controller automatically identifies the interface type and communication protocol of the connected device through its built-in multi-interface adapter;

[0068] S2. Based on the identification results, the PLC controller configures the communication protocol, including setting communication parameters and data format;

[0069] The S3 and PLC controllers collect real-time operating data from connected devices through the configured communication protocol, process the collected operating data, and obtain the processing results.

[0070] S4. Based on the obtained processing results and preset control logic, the PLC controller controls the connected devices. The control logic can be customized according to actual needs, including sequential control, timing control, conditional control, etc. It also coordinates the control of connected devices through networking with other PLC controllers.

[0071] S5. During the control process, the operating status of the equipment is monitored in real time through the fault diagnosis module of the PLC controller. If an abnormality is detected, the PLC controller will immediately trigger the alarm mechanism and send the fault information to relevant personnel through multiple communication interfaces.

[0072] The working principle of the above technical solution is as follows: The PLC controller first automatically identifies the interface type and communication protocol of the connected device through its built-in multi-interface adapter. This process utilizes advanced signal processing technology to parse the interface signals and determine the communication protocol to be used. Based on the identification results, the PLC controller configures the communication protocol, including setting communication parameters and data formats, to ensure unimpeded communication with the connected device. After configuring the communication protocol, the PLC controller collects the operating data of the connected device in real time and processes the collected operating data to obtain processing results. These processing results can be used to achieve precise control of the device and support data storage and transmission, facilitating subsequent data analysis and fault diagnosis. Based on the obtained processing results and preset control logic, the PLC controller controls the connected device. The control logic can be customized according to actual needs, including sequential control, timing control, and conditional control. Simultaneously, through networking with other PLC controllers, collaborative control of the connected device is achieved. During the control process, the PLC controller's fault diagnosis module monitors the operating status of the device in real time. If an abnormality is detected, the PLC controller will immediately trigger an alarm mechanism and send fault information to relevant personnel through multiple communication interfaces for timely handling of the abnormality.

[0073] The advantages of the above technical solution are as follows: Through built-in multi-interface adapters and automatic identification functions, the PLC controller can adapt to various interface types and communication protocols of connected devices, providing more flexible application scenarios and broader compatibility; the PLC controller can automatically identify and configure communication protocols without manual intervention, greatly simplifying the configuration process and improving configuration accuracy and reliability; the PLC controller collects and processes the operating data of connected devices in real time, obtaining real-time processing results. This allows for timely understanding of the equipment's operating status, supports precise control of the equipment, and provides a foundation for subsequent data analysis and fault diagnosis; the control logic can be customized according to actual needs, including sequential control, timing control, and conditional control. This enables the PLC controller to flexibly respond to various control scenarios, improving control accuracy and adjustability; the PLC controller monitors the equipment's operating status in real time through a fault diagnosis module. Once an abnormality is detected, an alarm mechanism is triggered immediately, and fault information is sent to relevant personnel through multiple communication interfaces, helping to handle abnormal situations promptly and ensuring production and equipment safety.

[0074] In one embodiment of the present invention, S1 includes:

[0075] S11. Start the PLC controller, execute the initialization program, and activate the built-in multi-interface adapter. Scan the available physical interfaces through the adapter, including serial ports, network ports, and USB ports, and generate an interface list.

[0076] S12. The adapter sends a general probe signal to each interface and waits for a response from the connected device. Upon receiving the response signal, the adapter analyzes the characteristics of the response signal, including signal strength and waveform. By comparing with a preset interface type feature library, the interface type is initially identified.

[0077] S13. If the initial identification fails, the adapter sends a probe signal again to obtain the interface information. Based on the obtained interface information, the adapter compares the interface type feature library again to determine the interface type; such as RS-232, RS-485, Ethernet port *4, 485 / 232 (DB9) interface *2.

[0078] S14. Based on the determined interface type, the adapter further sends a protocol probe packet. The adapter analyzes the response packet returned by the device, checks the matching degree of specific identifiers, and classifies the protocols using a protocol feature library and machine learning algorithms.

[0079] S15. If the protocol identification result is still uncertain, the adapter will initiate multiple rounds of interactive verification, which will enhance the identification accuracy by sending probe signals and receiving feedback multiple times; and return the determined interface type and communication protocol to the main program of the PLC controller.

[0080] The working principle of the above technical solution is as follows: After the PLC controller starts, it executes the initialization program and activates the built-in multi-interface adapter. The adapter scans available physical interfaces, such as serial ports, network ports, and USB ports, and generates an interface list. The adapter sends a common probe signal to each interface and waits for a response from the connected device. Based on the characteristics of the response signal, such as signal strength and waveform, the adapter initially identifies the interface type. If the initial identification fails, the probe signal is sent again, and the interface type is determined based on the acquired interface information, such as RS-232, RS-485, Ethernet port, etc. Based on the determined interface type, the adapter sends protocol probe packets, which contain specific identifiers for different communication protocols. The adapter analyzes the response packets returned by the device, checks the matching degree of specific identifiers, and classifies the protocols using a protocol feature library and machine learning algorithms. If there is uncertainty in the protocol identification result, the adapter initiates multiple rounds of interactive verification. The accuracy of identification is enhanced by sending probe signals and receiving feedback multiple times. Finally, the determined interface type and communication protocol are returned to the main program of the PLC controller.

[0081] The advantages of the above technical solution are as follows: By sending general probe signals and analyzing the responses of the equipment, the adapter can automatically identify the interface type and communication protocol without manual setting or configuration; after the PLC controller starts, the adapter can quickly scan and identify available physical interfaces and complete initialization and configuration in a short time, improving system startup speed; the adapter can identify multiple interface types, including serial ports, network ports, and USB ports, as well as multiple communication protocols, such as RS-232, RS-485, and Ethernet, providing broad compatibility; through multi-round interactive verification and machine learning algorithm support, the adapter can continuously improve identification accuracy, ensuring that the finally determined interface type and communication protocol are accurate; the automatic identification and configuration function reduces the need for manual setting, reduces human error and configuration time, and improves system stability and reliability.

[0082] In one embodiment of the present invention, S2 includes:

[0083] S21. After receiving the interface type and communication protocol identification results returned by the adapter, the PLC controller retrieves the corresponding communication protocol configuration template from the internal database.

[0084] S22, the PLC controller searches the retrieved configuration template, extracts the parameters required for the communication protocol, and adjusts the parameters according to actual needs through the communication parameter configuration options provided by the user interface;

[0085] S23. The PLC controller generates a communication parameter list based on the configuration template and the adjusted parameters, and stores the communication parameter list in an internal register.

[0086] S24. The PLC controller initializes the corresponding physical interface according to the interface type and sets the physical layer parameters of the interface. The physical layer parameters include serial port configuration or network port configuration. For application layer protocols, the PLC controller loads the corresponding protocol stack and library files, including encoders, decoders and state machines.

[0087] S25. After configuration, the PLC controller initiates a connection test, sends a test data packet to the connected device, and waits for a response. The PLC controller analyzes the test response to verify the stability of the communication link and the integrity of the data.

[0088] S26. If the test fails, the PLC controller will record the error message and reconfigure or provide an error message.

[0089] The working principle of the above technical solution is as follows: After receiving the interface type and communication protocol identification results returned by the adapter, the PLC controller retrieves the corresponding communication protocol configuration template from its internal database. Then, based on the retrieved configuration template, it extracts the various parameters required by the communication protocol. These parameters may include communication rate, data bits, parity bits, stop bits, etc. According to actual needs, the PLC controller adjusts the parameters through the communication parameter configuration options provided by the user interface. Then, it generates a communication parameter list and stores it in an internal register for later use. Based on the interface type, the PLC controller initializes the corresponding physical interface and sets the physical layer parameters of the interface, such as serial port configuration or network port configuration. For application layer protocols, the PLC controller loads the corresponding protocol stack and library files, including encoders, decoders, and state machines, to ensure normal communication. After configuration, the PLC controller initiates a connection test, sends test data packets to the connected device, and waits for a response. The PLC controller analyzes the test response to verify the stability and data integrity of the communication link. If the test fails, the controller records the error information and, as needed, reconfigures or provides error prompts for user intervention and adjustment.

[0090] The advantages of the above technical solution are as follows: The entire process is highly automated, automatically selecting appropriate configuration templates based on interface type and communication protocol. Users can also adjust parameters through the user interface as needed, ensuring system flexibility. Automatic retrieval and generation of communication parameter lists avoids the complexity of manual configuration, reduces human error, and improves configuration efficiency. Connection testing and data packet transmission quickly identify communication link problems and perform error diagnosis. Simultaneously, it supports automatic reconfiguration or provides error prompts, facilitating timely adjustments by users and ensuring communication link stability. Because the solution can be initialized based on interface type and load the corresponding application layer protocol, it supports various physical interfaces and communication protocols, meeting diverse industrial needs. Throughout the process, the PLC controller verifies the stability and data integrity of the communication link through connection testing, helping to ensure system reliability and stability and reducing the risk of system failure. The automated communication parameter configuration and initialization process reduces the need for manual intervention, lowers labor costs, and improves productivity. Furthermore, rapid error diagnosis and adjustment reduce system downtime and lower operating costs.

[0091] In one embodiment of the present invention, S22 includes:

[0092] The PLC controller extracts the basic parameters required for the communication protocol from the retrieved configuration template. These basic parameters include baud rate, data bits, stop bits, and parity method.

[0093] The PLC controller performs initial configuration of the extracted parameters, selecting electrical parameters and signal processing methods based on the interface type; the PLC controller provides communication parameter configuration options through the user interface, allowing users to fine-tune the parameters as needed;

[0094] After the parameter configuration is completed, the PLC controller performs parameter verification and conflict detection. If there is a parameter conflict or configuration error, the controller will provide error messages and solutions, and the user can make corrections according to the error messages and solutions.

[0095] During operation, the PLC controller monitors the real-time operating status and communication quality of the equipment, and dynamically adjusts communication parameters based on the operating status and communication quality.

[0096] The working principle of the above technical solution is as follows: The PLC controller first extracts the basic parameters required for the communication protocol from the preset configuration template, such as baud rate, data bits, stop bits, and parity method. Then, it selects the corresponding electrical parameters and signal processing methods according to the interface type for initial configuration. The controller provides communication parameter configuration options through the user interface, allowing users to fine-tune the parameters according to specific needs. The user interface adopts a graphical design, intuitively displaying the configuration process and supporting multi-language switching to improve user experience. After configuration, the PLC controller performs parameter verification and conflict detection to ensure that the configured parameters meet the requirements of the communication protocol and the electrical characteristics of the equipment. If parameter conflicts or configuration errors are found, the controller will provide corresponding error messages and solutions, which users can correct according to the prompts. The configured parameters are stored in the internal memory and can be exported to a file for backup and sharing. Simultaneously, the controller also supports importing configuration parameters from a file, enabling quick restoration and migration of configurations, improving work efficiency and convenience. During equipment operation, the PLC controller monitors the equipment's operating status and communication quality in real time, dynamically adjusting communication parameters according to real-time conditions to ensure communication stability and reliability.

[0097] The effects of the above technical solution are as follows: The PLC controller can extract parameters from preset configuration templates and provide configuration options through the user interface. Users can fine-tune the parameters as needed, achieving automated configuration of communication parameters and reducing the risk of manual operation and configuration errors. The user interface adopts a graphical design, intuitively displaying the parameter configuration process, supporting multi-language switching, and allowing users to quickly adjust parameter values ​​through mouse dragging, sliders, etc., and preview the configuration effect in real time, improving the visualization and ease of use of the configuration. After configuration, the PLC controller performs parameter verification and conflict detection to ensure that the configured parameters meet the requirements of the communication protocol and the electrical characteristics of the equipment, reducing the occurrence of configuration errors and improving the stability and reliability of the communication system. The controller supports exporting configuration parameters as files for backup and sharing, and also supports importing configuration parameters from files, enabling quick restoration and migration of configurations, improving work efficiency and convenience. During equipment operation, the PLC controller can monitor the operating status and communication quality of the equipment in real time, dynamically adjusting communication parameters according to the real-time situation to ensure the stability and reliability of communication, improving the system's responsiveness and adaptability.

[0098] In one embodiment of the present invention, the PLC controller monitors the real-time operating status and communication quality of the device during operation, and dynamically adjusts communication parameters based on the operating status and communication quality, including:

[0099] The PLC controller acquires real-time operating status data of connected devices, such as temperature, current, and voltage, through built-in sensors and interface circuits. Furthermore, the PLC controller monitors communication quality via the communication link, including key indicators such as bandwidth utilization, latency, and packet loss rate.

[0100] The PLC controller stores the acquired operating status and communication quality data in a database, performs historical data analysis and trend prediction through a built-in trend prediction model, and conducts big data analysis to identify potential problems with the equipment and bottlenecks in the communication link.

[0101] Based on the trend prediction model, the communication demand in the future period is predicted;

[0102] Based on the results of status monitoring and communication quality assessment, a dynamic parameter adjustment strategy is developed;

[0103] Based on the established adjustment strategy, communication parameters such as baud rate, data bits, and stop bits are adjusted in real time. After the parameters are adjusted, the PLC controller re-evaluates the communication quality and verifies the adjustment effect.

[0104] If the verification passes, continue monitoring; if the verification fails, revise and adjust the strategy based on the new evaluation results.

[0105] The PLC controller records the results of each parameter adjustment and the changes in communication quality. Based on an adaptive learning algorithm, the controller continuously optimizes the parameter adjustment strategy.

[0106] The working principle of the above technical solution is as follows: The PLC controller acquires real-time operating status data of connected devices, such as temperature, current, and voltage, through built-in sensors and interface circuits, and monitors communication quality through the communication link, including key indicators such as bandwidth utilization, latency, and packet loss rate. The acquired operating status and communication quality data are stored in a database. Historical data analysis and trend prediction are performed using a built-in trend prediction model, along with big data analysis, to identify potential problems with the devices and bottlenecks in the communication link. Based on the trend prediction model, communication demands for a future period are predicted, providing a basis for parameter adjustment. A dynamic parameter adjustment strategy is formulated based on the results of status monitoring and communication quality assessment. During strategy formulation, various factors such as device characteristics, network environment, and business requirements are considered, and the optimal parameter adjustment scheme is generated through complex logical operations and conditional judgments. Based on the formulated adjustment strategy, communication parameters, such as baud rate, data bits, and stop bits, are adjusted in real time. After adjustment, the communication quality is re-evaluated to verify the adjustment effect. If the verification passes, monitoring continues; if the verification fails, the adjustment strategy is revised based on the new evaluation results. The PLC controller records the results of each parameter adjustment and the changes in communication quality, and continuously optimizes the parameter adjustment strategy based on the adaptive learning algorithm to adapt to changes in equipment and communication environment.

[0107] The effects of the above technical solution are as follows: By real-time monitoring of equipment operating status and communication quality, and the application of trend prediction models, equipment problems and communication link bottlenecks can be detected in a timely manner, communication needs can be predicted in advance, and the risk of production interruption caused by equipment failure or communication problems can be reduced; by dynamically adjusting communication parameters, the communication system can be optimized according to actual conditions, improving communication stability and reliability, reducing communication failure rate, and ensuring continuous operation of the production system; in the process of formulating adjustment strategies, multiple factors such as equipment characteristics, network environment, and business needs are considered, and the impact of various factors on communication quality can be comprehensively considered, making parameter adjustments more accurate and effective; by recording and analyzing the results of each parameter adjustment and changes in communication quality, adaptive learning algorithms are applied to continuously optimize the adjustment strategy, enabling the system to adapt to constantly changing environments and needs, and continuously improve communication efficiency and stability; by predicting equipment problems and communication needs, and dynamically adjusting parameters, equipment maintenance costs and communication system operating costs can be reduced, and the overall efficiency of the system can be improved.

[0108] In one embodiment of the present invention, S3 includes:

[0109] S31. The PLC controller constructs a data request frame according to the configured communication protocol. The data request frame includes a request header, a data segment, and a checksum. The controller sends the constructed data request frame to the connected device through the initialized communication interface.

[0110] S32. The connecting device receives the request frame, processes the request according to the communication protocol requirements, and generates a response frame containing running data.

[0111] S33: The PLC controller receives the response frame, parses it using the loaded protocol stack and decoders in the library files, and processes the parsed data to obtain the processed result. The preprocessing includes verification and filtering to check the integrity and validity of the data and remove noise and outliers.

[0112] The working principle of the above technical solution is as follows: The PLC controller constructs request headers, data segments, and checksums in communication data frames according to the configured communication protocol to ensure the correctness and integrity of the data. These data frames include requests to connected devices, such as obtaining specific operating data or performing a certain operation. The initialized communication interface is responsible for sending the constructed data request frames to the connected devices to trigger a device response. After receiving the request frame, the connected device processes the request according to the requirements of the communication protocol and generates a response frame containing operating data. This response frame contains the result of the request or the required data for further processing by the PLC controller. The PLC controller receives the response frame returned by the connected device and parses it using the decoder in the loaded protocol stack and library files. Preprocessing is performed during parsing, including verification and filtering, to ensure the integrity and validity of the data, while removing potential noise and outliers to improve the reliability and accuracy of the data. The parsed and preprocessed data is further processed by the PLC controller to obtain the final processing result, including using the data for decision-making in the control system, displaying it on the human-machine interface, or storing it in a database for subsequent analysis.

[0113] The effects of the above technical solution are as follows: By using the configured communication protocol, the PLC controller can construct accurate data request frames and send them to the connected device through the communication interface, ensuring the reliability and accuracy of data transmission; the connected device can receive and process the request frames in a timely manner and generate response frames containing the required operating data. This ensures efficient data processing during transmission, reducing the possibility of delays and data loss; the PLC controller can parse the received response frames and perform data preprocessing using the decoders in the loaded protocol stack and library files. This includes verification and filtering to ensure data integrity and validity, while removing potential noise and outliers, improving data quality and reliability; through effective data communication and processing, the system can operate more stably. Accurate data transmission and processing help ensure the normal operation of the system, reduce the risk of system errors, and improve the stability and reliability of the production process; by optimizing the data communication and processing flow, the system can obtain the required operating data more quickly and perform corresponding control and adjustments. This helps improve the efficiency and performance of the production process, reducing production costs and resource waste.

[0114] In one embodiment of the present invention, step S4 includes:

[0115] S41, the PLC controller generates a sequence of control instructions based on the processing results and the preset control strategy, and encodes and formats the sequence of control instructions to obtain a control frame under a specific communication protocol;

[0116] S42. The PLC controller transmits control frames to the connected device through the communication interface. After receiving the control frames, the connected device executes corresponding actions or adjusts parameters.

[0117] S43. During execution, the PLC controller coordinates with other PLC controllers, exchanges information and synchronizes instructions through the network, and assigns tasks according to equipment status, priority and preset rules.

[0118] The working principle of the above technical solution is as follows: The PLC controller generates a sequence of control instructions based on the processing results and preset control strategies. These instructions may involve equipment start / stop, speed adjustment, parameter setting, etc. After encoding and formatting, the generated instruction sequence yields a control frame under a specific communication protocol. The PLC controller transmits the encoded control frame to the connected device through the communication interface. Upon receiving the control frame, the connected device executes the corresponding action or adjusts parameters according to the instructions. These actions may include machine start / stop, speed adjustment, valve opening / closing, etc. During execution, the PLC controller coordinates with other PLC controllers, exchanging information and synchronizing instructions through the network. Task allocation and scheduling are performed based on equipment status, priority, and preset rules to ensure coordinated system operation. The PLC controller also includes event-driven control logic, capable of responding to specific events or conditions to trigger control actions. This allows the system to make corresponding adjustments and processing based on real-time changes, improving the system's flexibility and adaptability. The control logic can be configured and modified through the user interface, supporting multiple control methods and strategies. This makes system management and maintenance more convenient, allowing operators to flexibly adjust and optimize according to actual needs.

[0119] The effects of the above technical solution are as follows: The PLC controller can quickly generate a sequence of control instructions based on the processing results and preset control strategies, and encode and format them into control frames under a specific communication protocol, thereby achieving efficient transmission of control instructions; the connected device can receive the control frames transmitted by the PLC controller and execute corresponding actions or adjust parameters according to the instructions in them, thereby achieving precise control and adjustment of the device; the PLC controller can coordinate with other PLC controllers, exchange information and synchronize instructions through the network, and allocate tasks according to device status, priority, and preset rules, thereby ensuring coordinated operation and resource optimization of the system; the PLC controller has event-driven control logic, which can respond to specific events or conditions to trigger control actions, thereby achieving flexible response and adjustment to real-time changes in the system; the control logic can be configured and modified through the user interface, supporting multiple control methods and strategies, making system management and maintenance more convenient and flexible.

[0120] In one embodiment of the present invention, S43 includes:

[0121] PLC controllers are connected via a network based on communication protocols (such as Modbus, Profinet, EtherNet / IP); each PLC controller is assigned a unique identifier or address in the network so that other controllers can identify it.

[0122] When the PLC controller starts up, it automatically performs network detection and uses the network to exchange information with other PLC controllers in real time, and synchronizes the information based on timestamps; the real-time information includes equipment status, operating data and error information;

[0123] Each PLC controller monitors the status of the equipment under its control, including operating status, fault status, and maintenance requirements. The PLC controller evaluates the priority of the equipment based on its real-time status, historical data, and preset rules.

[0124] Based on equipment status, priority, and preset rules, and using a distributed decision-making algorithm, PLC controllers collaborate to determine the tasks to be executed and their priorities.

[0125] During the task allocation process, the resource utilization of each PLC controller is monitored in real time through the resource manager, and dynamic adjustments are made through the load balancing algorithm.

[0126] Based on the results of collaborative decision-making, each PLC controller generates corresponding control instructions. These instructions are synchronized via the network to ensure that all controllers begin executing tasks at the same time. An instruction confirmation mechanism is also introduced to ensure that each controller successfully receives and executes the instructions.

[0127] In the process of collaborative control, if a conflict occurs, including situations where multiple controllers compete for the same resource or execute conflicting instructions, the controllers will resolve the conflict by detecting instruction conflicts and resource contention in the network and employing an arbitration mechanism. The arbitration mechanism can be based on priority, timestamps, random algorithms, etc., to ensure the fairness of resource allocation and task execution.

[0128] The PLC controller continuously collects data during collaborative control, including task execution results, equipment status changes, and network performance. Utilizing data from mobile phones and employing deep learning algorithms for self-learning, the controller continuously optimizes collaborative decision-making and task allocation algorithms.

[0129] The working principle of the above technical solution is as follows: Each PLC controller performs network detection upon startup and establishes a connection via a communication protocol. Each controller is assigned a unique identification code or address for identification and communication with other controllers. PLC controllers exchange information in real time via the network, including device status, operating data, and error information, and use timestamps for information synchronization to ensure data consistency among controllers. Each PLC controller monitors the status of the devices under its control, such as operation, faults, and maintenance needs, and evaluates device priorities based on real-time status, historical data, and preset rules. Based on device status, priorities, and preset rules, PLC controllers collaboratively make decisions using a distributed decision-making algorithm to determine the tasks to be executed and their priorities. The resource manager monitors each PLC controller in real time. The PLC controller optimizes resource utilization and dynamically adjusts it using a load balancing algorithm to ensure rational resource use. Based on the results of collaborative decision-making, each PLC controller generates corresponding control instructions and synchronizes them through the network to ensure that all controllers start executing tasks at the same time. An instruction confirmation mechanism is introduced to ensure correct instruction execution. In case of conflicts, the controller detects instruction conflicts and resource contention in the network and uses an arbitration mechanism to resolve conflicts, ensuring fairness in resource allocation and task execution. The PLC controller continuously collects data and uses deep learning algorithms for self-learning to continuously optimize the collaborative decision-making and task allocation algorithms, thereby improving system performance and efficiency.

[0130] The effects of the above technical solution are as follows: Real-time information exchange and synchronization mechanisms ensure the accuracy and real-time nature of information transmission between PLC controllers, enabling the system to respond promptly to changes in equipment status and task requirements; resource managers and load balancing algorithms monitor and adjust the resource utilization of each PLC controller in real time, avoiding excessive resource occupation or idleness and improving system resource utilization efficiency; the introduction of conflict detection and arbitration mechanisms effectively resolves resource competition and instruction conflicts between multiple controllers, ensuring fairness and smoothness in resource allocation and task execution; PLC controllers continuously collect data and use deep learning algorithms for self-learning, optimizing collaborative decision-making and task allocation algorithms, improving the system's adaptability and intelligence, and enabling the system to better adapt to complex industrial environments and changes; collaborative control and optimization algorithms improve system stability and reliability, reducing the risk of system crashes and production interruptions due to single-point failures or insufficient resources, and improving system production efficiency and reliability.

[0131] In one embodiment of the present invention, step S5 includes:

[0132] The fault diagnosis module of the S51 PLC controller receives status information and operating data from the connected device in real time. Through pattern recognition and machine learning algorithms, it performs real-time analysis and prediction of status information based on the built-in fault diagnosis model to identify potential faults or anomalies.

[0133] S52. If an abnormal situation is detected, the fault diagnosis module will immediately trigger an alarm mechanism, such as an audible and visual alarm, or an SMS notification. For serious faults, the fault diagnosis module will immediately trigger an emergency shutdown or protection measures.

[0134] S53. At the same time, the PLC controller records fault information, including fault type, occurrence time, and related parameters, and stores it in internal memory or external database.

[0135] S54. The fault diagnosis module performs in-depth analysis and diagnosis of fault information through the built-in fault analysis model. Based on the results of in-depth analysis and diagnosis, it determines the cause of the fault and generates a solution.

[0136] S55. Send the cause of the fault and the solution to relevant personnel through various communication methods, such as SMS, email or dedicated APP notification. After receiving the cause of the fault and the solution, the relevant personnel shall take appropriate action.

[0137] The working principle of the above technical solution is as follows: The fault diagnosis module of the PLC controller receives status information and operating data transmitted from connected devices in real time. Pattern recognition algorithms and machine learning algorithms analyze and predict the received data in real time to identify potential faults or anomalies. The fault diagnosis module monitors the data, and if an anomaly is detected, it immediately triggers an alarm mechanism. For serious faults, it may immediately take emergency shutdown or other protective measures to avoid further damage to equipment or personnel. The PLC controller records fault information, including fault type, occurrence time, and related parameters. This information is usually stored in internal memory or an external database for subsequent analysis and maintenance. The fault diagnosis module performs in-depth analysis and diagnosis of the recorded fault information through a built-in fault analysis model. Based on the analysis and diagnosis results, it determines the cause of the fault and generates corresponding solutions. The fault diagnosis module sends the fault cause and solution to relevant personnel through various communication methods such as SMS, email, or dedicated APP notifications. After receiving the notification, relevant personnel will take appropriate measures, such as repairing equipment or replacing parts, to restore the system to normal operation.

[0138] The above technical solution achieves the following effects: By receiving and analyzing equipment status information in real time, it can promptly identify potential faults or anomalies, allowing for proactive measures to prevent production losses due to prolonged equipment downtime. Upon detecting an anomaly, the system can immediately trigger an alarm mechanism and implement corresponding emergency shutdown or protection measures to ensure the safety of equipment and personnel, minimizing losses. Recording and storing fault information aids in subsequent analysis and diagnosis, providing data support for fault handling and a basis for long-term monitoring and improvement of equipment operating status. Based on a built-in fault analysis model, the system can deeply analyze fault information, accurately determine the cause of the fault, and generate corresponding solutions, improving the efficiency and accuracy of fault handling. Fault information and solutions are promptly sent to relevant personnel via various communication methods such as SMS, email, or a dedicated app notification, ensuring timely and accurate information transmission and helping relevant personnel quickly take appropriate action.

[0139] In one embodiment of the present invention, a computer program product includes a computer program / instruction that, when executed by a processor, implements a control method for an integrated PLC controller supporting multiple interfaces and multiple communication protocols as described above.

[0140] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A control method of an integrated PLC controller supporting multiple interfaces and multiple communication protocols, characterized by, The method comprises: S1, the PLC controller automatically identifies the interface type and communication protocol of the connected device through the built-in multi-interface adapter; S2, according to the identification result, the PLC controller configures the communication protocol, which includes setting the communication parameters and data format; S3, the PLC controller collects the running data of the connected device in real time through the configured communication protocol, processes the collected running data, and obtains the processing result; S4, based on the obtained processing result and the preset control logic, the PLC controller controls the connected device and cooperatively controls the connected device through networking with other PLC controllers; S5, during the control process, the running state of the device is monitored in real time through the fault diagnosis module of the PLC controller; if an abnormal condition is found, the PLC controller will immediately trigger the alarm mechanism and send the fault information to the relevant personnel through multiple communication interfaces; The S1 comprises: S11, start the PLC controller, execute the initialization program, activate the built-in multi-interface adapter, scan the available physical interfaces through the adapter, and generate an interface list; S12, the adapter sends a general probe signal to each interface and waits for the response of the connected device, obtains the response signal, and analyzes the characteristics of the response signal through the comparison with the preset interface type characteristic library to preliminarily identify the interface type; S13, if the preliminary identification fails, the adapter sends the probe signal again to obtain the interface information, compares the interface type characteristic library again according to the obtained interface information to determine the interface type; S14, based on the determined interface type, the adapter further sends a protocol probe package, analyzes the response package returned by the device, checks the matching degree of the specific identifier, and classifies the protocol by using the protocol characteristic library and machine learning algorithm; S15, if the protocol identification result still has uncertainty, the adapter starts multiple rounds of interactive verification to enhance the identification accuracy by sending the probe signal multiple times and receiving the feedback; and returns the determined interface type and communication protocol to the main program of the PLC controller; The S2 comprises: S21, after the PLC controller receives the interface type and communication protocol identification result returned by the adapter, the corresponding communication protocol configuration template is searched from the internal database; S22, the PLC controller searches the searched configuration template, extracts each parameter required by the communication protocol, and adjusts the parameters through the communication parameter configuration options provided by the user interface according to the actual demand; S23, the PLC controller generates a communication parameter list according to the configuration template and the adjusted parameters, and stores the communication parameter list in the internal register; S24, the PLC controller initializes the corresponding physical interface according to the interface type, sets the physical layer parameters of the interface, and loads the corresponding protocol stack and library file for the application layer protocol; S25, after the configuration is completed, the PLC controller initiates a connection test, sends a test data packet to the connected device, and waits for a response, the PLC controller analyzes the test response, verifies the stability of the communication link and the data integrity; S26, if the test fails, the PLC controller records the error information and reconfigures or provides an error prompt.

2. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 1, wherein The S22 comprises: The PLC controller extracts various basic parameters required by the communication protocol from the retrieved configuration template, including baud rate, data bits, stop bits, and check mode; The PLC controller performs preliminary configuration on the extracted parameters, selects electrical parameters and signal processing methods according to the interface type; the PLC controller provides communication parameter configuration options through the user interface, and the user fine-tunes the parameters according to the requirements; After completing the parameter configuration, the PLC controller performs parameter verification and conflict detection, and if there is a parameter conflict or configuration error, the controller gives an error prompt and solution, and the user corrects according to the error prompt and solution; In the running process, the PLC controller real-time device running state and communication quality, according to the running state and communication quality dynamic adjustment of communication parameters.

3. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 2, wherein, The PLC controller real-time device running state and communication quality, according to the running state and communication quality dynamic adjustment of communication parameters, comprising: The PLC controller acquires the running state data of the connected device through the built-in sensor and interface circuit, and the PLC controller monitors the communication quality through the communication link; The PLC controller stores the acquired running state and communication quality data in the database, analyzes the historical data and predicts the trend through the built-in trend prediction model; and performs big data analysis to identify potential problems of the device and bottlenecks of the communication link; Based on the trend prediction model, the communication demand in the future period of time is predicted; According to the results of state monitoring and communication quality evaluation, a dynamic parameter adjustment strategy is developed; Based on the developed adjustment strategy, the communication parameters are adjusted in real time, and after the parameter adjustment, the PLC controller reevaluates the communication quality to verify the adjustment effect; If the verification is passed, continue to monitor; if the verification fails, a new adjustment strategy is developed according to the new evaluation results; The PLC controller records the results of each parameter adjustment and the changes of the communication quality, and based on the adaptive learning algorithm, the controller continuously optimizes the parameter adjustment strategy.

4. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 1, wherein, The S3 comprises: S31, the PLC controller constructs a data request frame according to the configured communication protocol, and the controller sends the constructed data request frame to the connected device through the initialized communication interface; S32, the connected device receives the request frame, processes the request according to the requirements of the communication protocol, and generates a response frame containing running data; S33, the PLC controller receives the response frame, uses the loaded protocol stack and the decoder in the library file to analyze the response frame, and processes the analyzed data to obtain the processed result.

5. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 1, wherein, The S4 comprises: S41, the PLC controller generates a control instruction sequence according to the processing result and the preset control strategy, encodes and formats the control instruction sequence, and obtains a control frame under a specific communication protocol; S42, the PLC controller transmits the control frame to the connected device through a communication interface, and the connected device performs corresponding actions or adjusts parameters after receiving the control frame; S43, during the execution process, the PLC controller cooperates with other PLC controllers, exchanges information and synchronizes instructions through a network, and allocates tasks according to device states, priorities and preset rules.

6. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 5, wherein, The S43 comprises: The PLC controllers are connected based on a communication protocol and through a network; each PLC controller is assigned a unique identification code or address in the network; The PLC controller automatically performs network detection when starting, and exchanges real-time information between the PLC controllers through the network, and synchronizes information based on time stamps; Each PLC controller monitors the state of the device under its control, and the PLC controller evaluates the priority of the device based on the real-time state, historical data and preset rules of the device; Based on a distributed decision-making algorithm, the PLC controllers make collaborative decisions based on device states, priorities and preset rules to determine the tasks to be performed and the priorities of the tasks; During task allocation, the resource manager monitors the resource utilization of each PLC controller in real time, and dynamically adjusts through a load balancing algorithm; According to the results of the collaborative decision, each PLC controller generates corresponding control instructions, During the collaborative control process, if a conflict occurs, the controller detects instruction conflicts and resource competition in the network, and uses an arbitration mechanism to resolve the conflict; The PLC controller continuously collects data during the collaborative control process, and the controller uses the data collected through the mobile phone and performs self-learning based on a deep learning algorithm to continuously optimize the collaborative decision-making and task allocation algorithm.

7. The control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols according to claim 1, wherein, The S5 comprises: S51, the fault diagnosis module of the PLC controller receives state information and running data from the connected device in real time, analyzes and predicts the state information in real time based on the built-in fault diagnosis model through pattern recognition algorithm and machine learning algorithm, and identifies potential faults or abnormalities; S52, if an abnormal situation is found, the fault diagnosis module will immediately trigger an alarm mechanism, and for serious faults, the fault diagnosis module will immediately trigger an emergency shutdown or protection measure; S53, at the same time, the PLC controller records the fault information and stores it in the internal storage or external database; S54, the fault diagnosis module analyzes and diagnoses the fault information in depth based on the built-in fault analysis model, judges the fault cause based on the analysis and diagnosis results, and generates a solution; S55, the fault cause and solution are sent to relevant personnel through various communication methods, and the relevant personnel receive the fault cause and solution and take corresponding measures.

8. A computer program product comprising computer programs / instructions, characterized in that, The computer program / instructions are executed by the processor to implement the control method of the integrated PLC controller supporting multiple interfaces and multiple communication protocols as claimed in any one of claims 1-7.

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