Autonomous Web Server for Industrial I/O Access
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Solution Overview
Problem
Industrial control systems lack direct and efficient access to input and output points for remote monitoring and troubleshooting, especially before the programmable logic controller is fully operational, and there is a risk of disruption from unsynchronized control data.
Innovation Solution
A Web server module that communicates directly with I/O modules independent of the programmable logic controller, allowing a Web-based HMI to operate during setup and troubleshooting, and providing rapid access to I/O data without burdening the programmable logic controller, using a connected messaging network and processing unit to manage data transmission and prevent conflicts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a Web server module communicates through the programmable logic controller to access I/O data, then the control system maintains a centralized control architecture, but the Web-based HMI cannot operate independently during setup and troubleshooting before the controller is fully operational
Solution Approach 1:
The patent segments the communication architecture by creating a separate communication path between the Web server module and I/O modules, independent of the programmable logic controller. This allows the Web-based HMI to operate autonomously during setup and troubleshooting, improving adaptability without significantly increasing overall system complexity.
2Speed
If the Web server module opens its own connections with I/O modules independent of the programmable logic controller, then rapid access to I/O data is provided without burdening the controller, but the risk of conflicting commands and unsynchronized control data increases
Solution Approach 1:
The patent introduces a message buffer as an intermediary between the Web server module and I/O modules. This buffer mediates data transmission, ensuring that rapid access to I/O data does not compromise control data synchronization. The buffer acts as a buffer zone that prevents direct conflicts between independent communication paths while maintaining reliability.
3Ease of operation
If direct communication between the Web server module and I/O modules is established, then remote monitoring and troubleshooting are enabled during initial setup, but the potential for command conflicts from multiple communication sources increases
Solution Approach 1:
The patent implements preliminary actions by establishing clear communication protocols and connection management rules before conflicts can occur. The system pre-defines how multiple communication sources (programmable logic controller and Web server module) should interact, preventing command conflicts during remote setup and troubleshooting operations.
4Reliability
If the programmable logic controller maintains exclusive control over all I/O communications, then control data synchronization is ensured, but the Web-based HMI cannot provide rapid access to I/O data without burdening the controller
Solution Approach 1:
The patent segments the communication responsibilities by allowing the Web server module to directly access I/O modules for data retrieval, while the programmable logic controller maintains control over critical control data flows. This segmentation enables rapid I/O data access for monitoring purposes without burdening the controller, while control data synchronization is maintained through the segmented architecture.
Data Source
AI summary
An autonomous Web server may be connected to an industrial control system to provide direct access to input and output points through connections between the Web server and the input and output points. Coordination with the programmable logic controller is implemented through a set of lock flags which prevent conflicts either between multiple Web connections or between Web connections and the control produced by the programmable logic controller.