AI Extension Module for PLC Process State Integration
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Solution Overview
Problem
Regular automation devices, such as programmable logic controllers (PLCs), lack the computing power necessary for artificial intelligence (AI) technology, and cloud-based AI solutions are not easily implementable for shop floor applications.
Innovation Solution
An extension device capable of performing computations using artificial neural networks is provided, which simplifies the integration of AI into industrial systems by accelerating computations and facilitating data exchange between the extension device and automation devices through a process state model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If regular automation devices (PLCs) are used, then the device complexity is low and ease of operation is good, but the computing power is insufficient for AI technology
Solution Approach 1:
The system is divided into two separate devices: a regular automation device (PLC) that maintains low complexity and an extension device that provides AI computing power. The automation device handles traditional control tasks while the extension device专门 handles AI computations, allowing each component to be optimized independently.
Solution Approach 2:
An extension device acts as an intermediary between the automation device and AI algorithms. This intermediary provides the necessary computing power for AI while maintaining compatibility with existing automation devices through standardized communication interfaces.
2Power
If cloud-based AI solutions are used, then AI computing power is available, but implementation difficulty increases for shop floor solutions
Solution Approach 1:
The extension device serves as a local intermediary that brings AI capabilities directly to the shop floor environment. It processes AI computations locally rather than requiring cloud connectivity, eliminating implementation barriers related to network dependency and data transmission.
Solution Approach 2:
The extension device is designed with universal interfaces that can connect to various automation devices and support multiple AI algorithms. This multi-functionality allows a single extension device to serve different application scenarios without requiring custom integration for each case.
3Speed
If AI computations are performed locally, then real-time monitoring and control are enabled, but the automation device requires additional computing resources
Solution Approach 1:
Computing resources are segmented between two devices: the automation device maintains its original resource allocation for traditional control tasks, while the extension device is dedicated to AI computations. This segmentation allows real-time processing without overloading the automation device.
Data Source
AI summary
An extension device for one or more automation devices in an industrial system is provided. Industrial data processing units capable of performing data processing based on one or more artificial neural networks are provided. To enable and/or accelerate one or more computations in an industrial system, thereby simplifying integration of artificial intelligence into the industrial system, and to simplify data exchange between an extension device capable of processing data using artificial intelligence and an automation device, one or more results of the one or more computations are obtained. The results indicate one or more states of the industrial system. The one or more results are provided via a process state model shared with the automation device to monitor and/or control the industrial system.