Cloud PLC Configuration via Compile-Time Controller Abstraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial automation systems face challenges due to proprietary technologies leading to strong dependencies, reduced interoperability, security issues, high costs, and limited integration with modern company software systems, along with vendor-specific hardware architectures and long lead times, which hinder efficient reconfiguration and optimization of production lines.
Innovation Solution
A cloud-based method for configuring and optimizing industrial automation systems by generating a compile-time representation of controller programs and configurations, allowing modifications via a cloud computing system, which abstracts major PLC functions across different technology platforms, enabling secure and non-intrusive connectivity for automatic deployment and integration with microservices enterprise architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proprietary technology and vendor-specific hardware architectures are used in industrial automation systems, then within-stack compatibility and system reliability are improved, but interoperability across different platforms is reduced, device complexity increases, and adaptability decreases
Solution Approach 1:
The patent introduces a cloud-based PLC service as an intermediary layer between control logic and hardware devices. This service virtualizes PLC functions and provides a standardized interface that works across different vendor-specific hardware architectures, thereby maintaining reliability while improving interoperability and adaptability.
Solution Approach 2:
The patent segments the PLC functionality into a virtualized service running in the cloud, separating it from the underlying hardware. This allows the control logic to be independent of vendor-specific hardware architectures, improving interoperability while maintaining system reliability through the virtualized abstraction layer.
2Ease of operation
If control code editing systems are kept local and tightly coupled with PLC hardware, then ease of operation for local programming is improved, but ease of repair and system maintenance are worsened, and adaptability to remote modifications is reduced
Solution Approach 1:
The cloud-based PLC service acts as an intermediary that enables both local and remote access to control code editing. Local programming remains easy through standard interfaces, while remote modifications become feasible through the cloud connection, improving maintenance ease without sacrificing local programming ease.
Solution Approach 2:
The patent adds a remote dimension to control code editing by introducing cloud-based access. This allows programming and maintenance activities to occur in both local and remote dimensions simultaneously, resolving the contradiction between local programming ease and system maintenance ease.
3Adaptability or versatility
If PLC functions are virtualized and moved to cloud-based infrastructure, then adaptability and ease of repair are improved, but device complexity and network dependency increase
Solution Approach 1:
The cloud-based PLC service serves as an intermediary that manages the complexity of virtualization remotely. While the underlying system becomes more adaptable through virtualization, the complexity is handled by the cloud service rather than requiring complex local infrastructure, thus improving adaptability while managing device complexity.
4Reliability
If vendor-specific hardware architectures and ASICs are used, then manufacturing precision and reliability are improved, but ease of manufacture is reduced due to long lead times and supply chain vulnerability
Solution Approach 1:
The cloud-based PLC service acts as an intermediary that replaces the need for vendor-specific hardware architectures and ASICs. By virtualizing PLC functions in the cloud, the system maintains controller reliability while dramatically improving ease of manufacture, as cloud services can be deployed rapidly without long hardware lead times or supply chain dependencies.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
In some aspects, the present disclosure relates to a method for configuring a controller of an industrial automation system via a network, the method comprising, obtaining, by a cloud computing system, a controller configuration and a controller program, generating, by the cloud computing system, based on the obtained controller configuration and the obtained controller program, a compile time representation of the controller allowing modification of the controller program and the controller configuration, and generating, by the cloud computing system, a modified controller program and / or a modified controller configuration, using the compile time representation of the controller, wherein the controller program defines runtime operation of the controller controlling a subsystem of the industrial automation system, and providing, by the cloud computing system via the network, the modified controller program and / or the modified controller configuration to the controller of the industrial automation system. Further aspects relate to a method for optimizing performance of an industrial automation system as well as to corresponding cloud computing systems and computer programs.