Cloud Operator Interface via Gateways for Remote Industrial Control
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Solution Overview
Problem
Conventional industrial automation systems require operator interfaces to be physically proximate to the controlled systems, limiting remote monitoring and control capabilities, as they share a common network with industrial controllers and have restricted data access.
Innovation Solution
A cloud-based operator interface system that utilizes cloud gateways to collect and transmit industrial data to a cloud platform, allowing remote monitoring and control through Internet-capable devices, with features like event-based notifications and contextual data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator interfaces are located in proximity to industrial controllers on a common network, then data access and control are reliable and fast, but remote monitoring and control capabilities are limited
Solution Approach 1:
A cloud gateway acts as an intermediary component that bridges the industrial controller network and the cloud platform. The gateway collects data from industrial controllers via a local network, transmits it to the cloud, and receives control commands from the cloud to execute locally. This intermediary enables remote access while maintaining data integrity and control reliability through standardized communication protocols and data formatting.
2Adaptability or versatility
If operator interfaces share a common network with industrial controllers, then system integration is simple and data access is direct, but the system lacks flexibility and adaptability for remote access
Solution Approach 1:
The system is segmented into three independent functional modules: (1) industrial controllers that execute control logic locally, (2) cloud gateways that handle data collection and transmission, and (3) cloud-based operator interfaces that provide remote access. This segmentation allows each component to be optimized independently and enables flexible deployment scenarios while maintaining simple local network integration.
Solution Approach 2:
The cloud gateway is designed as a universal component that can interface with multiple types of industrial controllers and protocols, translating diverse industrial data formats into standardized cloud-compatible formats. This multi-functionality enables the same gateway architecture to serve different industrial applications without requiring custom integration for each controller type.
3Loss of time
If operator interfaces are deployed locally near industrial systems, then response time is fast and control is immediate, but personnel must be physically present on the plant floor
Solution Approach 1:
The system performs preliminary data processing and formatting at the cloud gateway before transmission to the cloud platform. Data is pre-formatted according to cloud interface requirements, and control commands are pre-validated before being sent to the gateway for execution. This preliminary action reduces round-trip communication delays and ensures immediate local response capability while maintaining remote accessibility.
Data Source
AI summary
A cloud-based operator interface system is provided that runs as a cloud service on a cloud platform. The cloud-based operator interface system collects industrial data from one or more industrial systems via respective cloud gateway devices. A set of predefined operator interface screens are stored on cloud storage associated with the operator interface system, and delivered to authorized Internet-capable client devices upon request. The industrial data received from the cloud gateways can be delivered to the client devices from the cloud platform via the operator interface screens. Additional cloud-side services can correlate and analyzes the industrial data on the cloud platform to facilitate additional reporting, alarming, and notification features.