PLC equipment hardware module graphical layout configuration method based on scanning

Abstract

The invention relates to the field of industrial control automation, and provides a scanning-based PLC equipment hardware module graphical layout configuration method, which comprises the following steps: responding to module scanning operation, and collecting hardware module configuration information of current PLC equipment; performing parameter matching and module identification on the acquired hardware module configuration information and a PLC hardware library preset in upper computer software, and automatically constructing a corresponding graphical hardware layout; whether original engineering configuration corresponding to the current PLC equipment exists in upper computer software or not is judged, when the original engineering configuration exists, difference identification is conducted in the graphical hardware layout after different model parameters are recognized, and updated hardware module configuration information is loaded in a software interface; and when the original engineering configuration does not exist, loading the currently generated graphical hardware layout as a new engineering configuration to a software interface. According to the method, intelligent scanning, difference comparison and configuration multiplexing of module layout are realized through graphical automatic identification and configuration of a PLC equipment hardware module.

Description

Technical Field

[0001] This invention relates to the field of industrial control automation, and in particular to a graphical layout configuration method for PLC equipment hardware modules based on scanning. Background Technology

[0002] In industrial automation control systems, the PLC (Programmable Logic Controller) serves as the core control unit and is the primary link in realizing programmable control of the automation system. It is widely used in process control, equipment operation monitoring, communication systems, and ship automation. Engineers typically need to configure the system structure using PLC logic configuration software based on specific control requirements. This includes the selection and layout of various hardware components such as racks, power supplies, CPU modules, digital input / output modules, analog input / output modules, power supplies, and other hybrid and proprietary hardware. They also need to write the corresponding control logic to achieve automated control of the target system.

[0003] In existing technologies, PLC hardware configuration primarily relies on offline hardware configuration settings. Engineers manually select module names from the software's device library and add them to the engineering layout interface by dragging and dropping or double-clicking. They then sequentially set the rack structure, module order, and interface parameters to achieve industrial automation control for specific scenarios. While this method is relatively intuitive, in large control systems or scenarios with frequent module changes, it still suffers from cumbersome layout adjustments, low configuration efficiency, and high module error rates, severely impacting system deployment and debugging efficiency. Specifically, if a scenario requiring a rearrangement occurs during debugging, engineers must manually change the position or model of modules repeatedly. If the system is large and requires many hardware modules, manually adding hardware modules becomes inefficient and prone to errors.

[0004] Furthermore, when reusing systems with similar control scenarios or upgrading existing projects, the existing PLC hardware module layout cannot achieve the comparison function of the original project, making it difficult to reuse the original control project and thus wasting resources. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide a scanning-based graphical layout configuration method for PLC device hardware modules, thereby solving the problems of existing technologies where PLC device module layout configuration relies on manual construction, module changes require repeated editing, and project reuse efficiency is low. The above-mentioned objective of the present invention is achieved through the following technical solution: This invention provides a graphical layout configuration method for PLC device hardware modules based on scanning, including: The response module scan operation collects the hardware module configuration information of the current PLC device. The collected hardware module configuration information is matched with the preset PLC hardware library in the host computer software to identify the parameters and automatically build the corresponding graphical hardware layout. Determine if the host computer software contains an existing project configuration corresponding to the current PLC device: When an existing project configuration exists, the currently scanned hardware module configuration information is compared with the original project configuration. After identifying the model parameters that differ, the differences are marked in the graphical hardware layout, and the updated hardware module configuration information is loaded in the software interface. If the existing project configuration does not exist, the currently generated graphical hardware layout will be loaded into the software interface as a new project configuration.

[0006] Furthermore, in response to module scanning operations, the hardware module configuration information of the current PLC device is collected, including: sending a scan request command to the PLC device through the host computer software or collecting the hardware module configuration information of the hardware modules in the PLC device when a hardware module change is detected.

[0007] Furthermore, the hardware module configuration information includes rack type, hardware model information, hardware version information, embedded version information, module data length, module online status, and its arrangement order in the rack.

[0008] Furthermore, the hardware module includes a rack, power supply, I / O module, hybrid module, and one or more functional modules with specified control or communication capabilities.

[0009] Furthermore, the PLC hardware library includes model identifiers, version information, graphic templates, data area lengths, logic channel configurations, and parameter configuration items corresponding to each type of hardware module.

[0010] Furthermore, the collected hardware module configuration information is matched with the preset PLC hardware library in the host computer software to identify modules and automatically construct the corresponding graphical hardware layout, including: By scanning and collecting the rack type and arrangement order in the hardware module configuration information, the matching rack graphic template resource is called from the PLC hardware library, the corresponding rack graphic is loaded in the bottom area of ​​the interface, and a rack information widget containing a unique number and installation information is generated. Based on the hardware model information, hardware version information, embedded version information and module online status in the hardware module configuration information, the module type at the corresponding position on the rack graphic is identified, and the matching graphic template is called from the PLC hardware library to load the corresponding module graphic and generate a module information table. The module information table includes hardware model information, hardware version information and module data length. The module data length, model, and version information are compared with the data area length recorded in the PLC hardware library. When the configuration is consistent and there are no abnormalities, the logical channel configuration information and parameter configuration items of each hardware module are generated. The logical channel configuration information includes the logical address range and channel planning.

[0011] Based on the arrangement of hardware modules in the rack, a complete graphical hardware layout structure is automatically synthesized and loaded into the software interface to form the current PLC equipment's graphical online engineering configuration.

[0012] Further, determine whether the host computer software contains an existing project configuration corresponding to the current PLC device: Respond to the online project comparison request and read the current online project configuration; Extract rack information and hardware module information from the online engineering configuration; Determine if there are any differences between the online project configuration and the original project configuration.

[0013] Furthermore, when an existing project configuration exists, the currently scanned hardware module configuration information is compared with the existing project configuration. After identifying any discrepancies in the model parameters, the differences are marked in the graphical hardware layout, and the updated hardware module configuration information is loaded into the software interface; including: When it is determined that there are differences between the configuration information of the online project configuration and the original project configuration, the identified difference modules will be visually marked with a specified color in the graphical hardware layout structure, and the corresponding difference field content will be displayed by calling the module information table. Once the content of the difference field is confirmed, the difference item is updated, and the updated graphical hardware layout is loaded into the software interface.

[0014] Compared with the prior art, the present invention has at least one of the following beneficial effects: This invention achieves intelligent scanning, difference comparison, and configuration reuse of PLC device hardware modules through graphical automatic identification and configuration. On the one hand, engineers only need to click the system scan function to automatically generate the layout configuration, reducing manual operation and error rate. On the other hand, during module changes or debugging, the system can quickly identify and update module information, improving configuration efficiency. Furthermore, this invention supports intuitively displaying the differences between the current system and the original project graphically, which facilitates project reuse and maintenance, significantly improving the convenience of project debugging and the accuracy of deployment. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the steps of the scanning-based graphical layout configuration method for PLC device hardware modules according to the present invention. Figure 2This is a layout diagram of the graphical layout configuration system for PLC device hardware modules in an embodiment of the present invention; Figure 3 This is a graphical layout configuration diagram of the PLC device hardware modules in an embodiment of the present invention; Figure 4 This is an engineering comparison diagram showing the graphical layout configuration of the PLC device hardware modules in an embodiment of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0017] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in this specification means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0018] First Embodiment In existing PLC system configuration practices, some software solutions have attempted to improve the efficiency of hardware layout configuration. For example, some solutions introduce system topology configuration functions into PLC programming software, allowing engineers to manually build the required system topology by dragging and dropping modules onto the editing interface or chassis backplane after understanding the hardware types supported by the selected PLC series, such as backplanes, I / O modules, and power modules. While this method improves the intuitiveness of operation, it still suffers from inefficiency and a high error rate due to reliance on manual selection and configuration, especially in scenarios with a large number of module types or frequent configuration changes. Another solution proposes a software-defined control approach, parametrically configuring sensors and controllers connected to the system. By allowing users to select I / O interface types, it automatically lists matching port resources and allows for custom port naming, enabling rapid mapping between port logic and physical resources. This type of method emphasizes flexibility and abstract configuration but does not involve scanning and automatically laying out the actual physical hardware structure of the PLC, nor does it support real-time configuration reconfiguration based on device operating status. Therefore, existing solutions mainly focus on module logic configuration and interface drag-and-drop operations, lacking an automatic perception and graphical layout generation mechanism based on underlying system information, making it difficult to meet the actual needs of engineering sites for fast, accurate, and reusable configuration.

[0019] To address the aforementioned issues as much as possible, this embodiment employs a system scanning method to scan the current system, including racks, power supplies, CPUs, digital input / output modules, analog input / output modules, and mixed-use and proprietary hardware modules. After scanning, all hardware modules are automatically displayed in the software interface in a layout configuration. When engineers modify the layout of hardware modules during system debugging, they do not need to modify each module individually in the software layout configuration; they only need to click the module scan function in the software, and the new layout configuration will be automatically generated.

[0020] When engineers upgrade an existing control system or reuse a similar system, they only need to click the system scan function. The software will automatically compare the differences between the original system and the currently online system modules, and display the differences in module type, parameter configuration of similar modules, and embedded version information of communication modules in the layout configuration. Engineers can then confirm and modify the information marked on each module in the layout configuration. The specific implementation method is as follows: like Figure 1 As shown, this invention provides a scanning-based graphical layout configuration method for PLC device hardware modules, which solves the problems of manually adding hardware modules in large control systems and the inability to quickly reuse existing projects through difference comparison. The method includes: The response module scan operation collects the hardware module configuration information of the current PLC device. The collected hardware module configuration information is matched with the preset PLC hardware library in the host computer software to identify the parameters and automatically build the corresponding graphical hardware layout. Determine if the host computer software contains an existing project configuration corresponding to the current PLC device: When an existing project configuration exists, the currently scanned hardware module configuration information is compared with the original project configuration. After identifying the model parameters that differ, the differences are marked in the graphical hardware layout, and the updated hardware module configuration information is loaded in the software interface. If the existing project configuration does not exist, the currently generated graphical hardware layout will be loaded into the software interface as a new project configuration.

[0021] Furthermore, in response to module scanning operations, the hardware module configuration information of the current PLC device is collected, including: sending a scan request command to the PLC device through the host computer software or collecting the hardware module configuration information of the hardware modules in the PLC device when a hardware module change is detected.

[0022] Furthermore, the hardware module configuration information includes rack type, hardware model information, hardware version information, embedded version information, module data length, module online status, and its arrangement order in the rack.

[0023] Furthermore, the hardware module includes a rack, power supply, I / O module, hybrid module, and one or more functional modules with specified control or communication capabilities. The hybrid module is a composite module integrating multiple signal interfaces, capable of simultaneously processing digital and analog input / output signals, suitable for scenarios with complex signal types or limited control cabinet space. The functional modules are those with specific control or communication capabilities, such as high-speed counting modules, pulse output modules, positioning modules, temperature acquisition modules, and communication expansion modules, used to achieve special purposes such as motion control, high-speed signal processing, or protocol communication.

[0024] Furthermore, the PLC hardware library includes model identifiers, version information, graphic templates, data area lengths, logic channel configurations, and parameter configuration items corresponding to each type of hardware module.

[0025] Furthermore, the collected hardware module configuration information is matched with the preset PLC hardware library in the host computer software to identify modules and automatically construct the corresponding graphical hardware layout, including: By scanning and collecting the rack type and arrangement order in the hardware module configuration information, the matching rack graphic template resource is called from the PLC hardware library, the corresponding rack graphic is loaded in the bottom area of ​​the interface, and a rack information widget containing a unique number and installation information is generated. Based on the hardware model information, hardware version information, embedded version information and module online status in the hardware module configuration information, the module type at the corresponding position on the rack graphic is identified, and the matching graphic template is called from the PLC hardware library to load the corresponding module graphic and generate a module information table. The module information table includes hardware model information, hardware version information and module data length. The module data length is compared with the data area length recorded in the PLC hardware library. When the configuration is consistent and there are no abnormalities, the logical channel configuration information and parameter configuration items of each hardware module are generated. The logical channel configuration information includes the logical address range and channel planning.

[0026] Based on the arrangement of hardware modules in the rack, a complete graphical hardware layout structure is automatically synthesized and loaded into the software interface to form the current PLC equipment's graphical online engineering configuration.

[0027] Specifically, the system first collects configuration information of the hardware modules through scanning, including rack type, module model, version information, module online status, and their arrangement order. Based on this collected data, the system automatically calls a graphic template matching the rack type and arrangement order from the preset PLC hardware library. Then, the rack graphic is loaded into the bottom area of ​​the software interface, and a widget with a unique number and installation information is generated for each rack, constructing a rack graphic structure consistent with the actual hardware.

[0028] After loading the rack diagram, the system continues to identify the installation location of each module in the rack based on the hardware module configuration information, including hardware model, version information, embedded version, and module online status. It then automatically retrieves the corresponding diagram template from the hardware module library. In this way, the system can load the corresponding module diagram onto the rack diagram and generate a detailed module information table, including parameters such as hardware model, hardware version, and module data length.

[0029] Next, the length of the scanned module data is compared with the standard module data area length in the hardware library to ensure that the module configuration is consistent and without anomalies. If the data length matches, the system will automatically generate the logical channel configuration for the module, including the logical address range, channel planning, etc., and configure the corresponding parameters to ensure that the module operates according to its intended function.

[0030] Finally, as Figure 3 As shown, based on the module arrangement order, a complete graphical hardware layout structure is automatically synthesized and loaded into the software interface. This layout structure allows engineers to intuitively view the hardware configuration of the current PLC device and perform subsequent verification, debugging, and configuration update operations. Figure 3This diagram illustrates the hardware module layout of a PLC system. The PLC system rack houses multiple hardware modules, including a power supply module, a CPU module, and various I / O modules. These modules are installed in slots within the rack according to a pre-defined arrangement. Each module connects via a slot, providing different functions and interfaces. This configuration enables complex automation control and monitoring tasks, ensuring the efficient operation of industrial equipment. The diagram shows the location of each module and graphically presents the connections and arrangement between modules, allowing engineers to intuitively view and manage the hardware modules in the PLC system. The type, model, and slot location of each module are clearly displayed in the diagram, facilitating subsequent operation and maintenance.

[0031] Further, determine whether the host computer software contains an existing project configuration corresponding to the current PLC device: Respond to the online project comparison request and read the current online project configuration; Extract rack information and hardware module information from the online engineering configuration; Determine if there are any differences between the online project configuration and the original project configuration.

[0032] Furthermore, when an existing project configuration exists, the currently scanned hardware module configuration information is compared with the existing project configuration. After identifying any discrepancies in the model parameters, the differences are marked in the graphical hardware layout, and the updated hardware module configuration information is loaded into the software interface; including: When it is determined that there are differences between the configuration information of the online project configuration and the original project configuration, the identified difference modules will be visually marked in the graphical hardware layout structure with a specified color / highlight, and the corresponding difference field content will be displayed by calling the module information table. Once the content of the difference field is confirmed, the difference item is updated, and the updated graphical hardware layout is loaded into the software interface.

[0033] Specifically, such as Figure 4 As shown, when responding to an online project comparison request, the configuration information of the current online project is read first. Figure 4 The hardware layout of the PLC equipment is demonstrated, including different types of modules and racks. Configuration information collected by the system through scanning is loaded into the host computer software. Based on this, the system extracts rack information and hardware module information from the online engineering configuration and compares them.

[0034] If the online project configuration differs from the original project configuration, the system will display the identified differences through a graphical hardware layout. The differing modules will be highlighted in red in the graphical layout for easy identification by engineers. Simultaneously, the system will access the module information table to display the specific differences in fields, such as hardware model, version number, and module parameters.

[0035] After confirming the differences, engineers can update the differences according to the system prompts. Once completed, the updated hardware module configuration information will be loaded into the software interface, thus completing the configuration synchronization. This process effectively simplifies debugging and system upgrades, ensuring the accuracy and consistency of the configuration.

[0036] Second Embodiment To further illustrate a specific implementation of this invention in practical applications, a detailed description is provided, particularly regarding the integrated application of PLC hardware library management, upper and lower computer communication mechanisms, module layout construction process, and engineering comparison functions. This embodiment demonstrates the complete closed loop of this invention in automated control systems, from hardware identification to graphical configuration, and from communication response to engineering difference analysis. It possesses strong practicality and engineering replicability, providing efficient and intuitive configuration support for PLC system deployments of different scales and types. The specific details are as follows: like Figure 2 As shown, this invention provides a scanning-based graphical layout configuration system for PLC device hardware modules. It employs the aforementioned graphical layout configuration method for PLC device hardware modules, including a PLC hardware library encompassing racks, power supplies, I / O modules, hybrid modules, special function module management, PLC-master-slave communication, module layout construction, and engineering comparison. Among these, The PLC hardware library is a basic hardware library that enables the management of components including racks, power supplies, I / O modules, hybrid modules, and special function modules. It includes selection guidance, hardware versions, embedded versions, images, data area lengths, data area definitions, and module parameter information for the aforementioned hardware.

[0037] The PLC communication module refers to the communication between the PLC logic configuration software and the PLC. Engineers can set up automatic response to hardware changes and manual scanning modes through the software interface.

[0038] Manual scan mode: Upon receiving a module scan message, the host computer sends an online scan request to the PLC. The PLC retrieves information including rack type, hardware model, hardware version, embedded version, module data length, and module online status via the communication bus protocol and replies to the host computer.

[0039] Automatic hardware change response mode: The PLC compares the two most recent communication bus information and sends the above information to the host computer when there is a change.

[0040] The module layout is constructed to allow the host computer to obtain system scan data via communication messages. First, the rack image is loaded at the bottom layer of the interface based on the rack model and its arrangement, creating an information rack widget. Second, the module image is loaded at the second layer based on the module's hardware model, version, and location information, creating a module information table containing hardware version information, embedded version information, and module data length. Finally, the logical addresses, channel plans, and parameters for each module are created, completing the online layout configuration. Depending on the response method, automatic hardware changes will directly load the layout configuration into the current project; manual scanning mode will temporarily store it in the online project.

[0041] The project comparison module allows engineers to use the online project comparison function. The PLC software compares the rack and module information in the current project with the same information in the online project. Differences are marked in red in the graphical module layout. Engineers can then click on the module based on the color markings to view the specific differences in the module information table.

[0042] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

[0043] It should be noted that the above embodiments can be freely combined as needed. The above description is only a preferred embodiment of the present invention. It should be pointed out that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A graphical layout configuration method for PLC device hardware modules based on scanning, characterized in that, Comprise: In response to the module scanning operation, collect the hardware module configuration information of the current PLC device; Match the collected hardware module configuration information with the preset PLC hardware library in the host computer software to identify the module and automatically build the corresponding graphical hardware layout; Determine whether the original engineering configuration corresponding to the current PLC device exists in the host computer software: When the original engineering configuration exists, compare the hardware module configuration information currently scanned with the original engineering configuration, identify the model parameters that exist differences, and perform difference identification in the graphical hardware layout, and load the updated hardware module configuration information in the software interface; When the original engineering configuration does not exist, load the generated graphical hardware layout as a new engineering configuration to the software interface.

2. The method of claim 1, wherein, In response to the module scanning operation, collect the hardware module configuration information of the current PLC device, including: sending a UDP scanning request instruction to the PLC device through the host computer software or collecting the hardware module configuration information of the hardware module in the PLC device when the hardware module changes is detected.

3. The method of claim 2, wherein, The hardware module configuration information includes rack type, hardware model information, hardware version information, embedded version information, module data length, module online state, and arrangement order in the rack.

4. The method of claim 3, wherein, The hardware module includes a rack, a power supply, an IO module, a hybrid module, and one or more functional modules with specified control or communication capabilities.

5. The method of claim 4, wherein, The PLC hardware library includes model identification, version information, graphical template, data area length, logic channel configuration, and parameter configuration items corresponding to each type of hardware module.

6. The method of claim 5, wherein, Match the collected hardware module configuration information with the preset PLC hardware library in the host computer software to identify the module and automatically build the corresponding graphical hardware layout, including: Call the matching rack graphical template resource from the PLC hardware library by scanning the rack type and arrangement order in the collected hardware module configuration information, load the corresponding rack graph in the interface bottom area, and generate rack information widgets containing unique number and installation information; Based on the hardware model information, hardware version information, embedded version information, and module online state in the hardware module configuration information, identify the module type at the corresponding position on the rack graph, and call the matching graphical template from the PLC hardware library to load the corresponding module graph and generate a module information table, which includes the hardware model information, hardware version information, and module data length; According to the comparison between the module data length and the data area length recorded in the PLC hardware library, when the configuration is consistent and there is no exception, generate the logic channel configuration information and the parameter configuration items of each hardware module, and the logic channel configuration information includes logic address range and channel planning; According to the arrangement order of the hardware modules in the rack, a complete graphical hardware layout is automatically synthesized and loaded to the software interface, forming a current PLC device graphical online engineering configuration.

7. The method of claim 6, wherein, It is judged whether there is an original engineering configuration corresponding to the current PLC device in the host computer software: In response to an online engineering comparison request, the current online engineering configuration is read; The rack information and the hardware module information in the online engineering configuration are extracted; It is judged whether there is a difference between the configuration information of the online engineering configuration and the original engineering configuration.

8. The method of claim 6, wherein, When there is the original engineering configuration, the hardware module configuration information currently scanned is compared with the original engineering configuration, the model parameters with differences are identified, the differences are marked in the graphical hardware layout, and the updated hardware module configuration information is loaded in the software interface; including: When it is judged that there is a difference between the configuration information of the online engineering configuration and the original engineering configuration, the identified difference module is visually marked in the graphical hardware layout structure with a specified color, and the module information table is called to display the corresponding difference field content; After confirming the difference field content, the difference item is updated, and the updated graphical hardware layout is loaded to the software interface.

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