Cloud-Based PLC Configuration for Remote IoT Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing programmable logic controllers (PLCs) in industrial applications operate in silos, making them difficult to modify and manage, lacking integration with IoT functionality and requiring manual coding for local control.
Innovation Solution
A method and apparatus that connect PLCs to a cloud network via a virtualization server, allowing users to create and manage smart PLC solutions through a graphical user interface on a user device, enabling the deployment of executable applications that can monitor and control PLCs remotely, integrate IoT functionality, and modify configurations dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PLCs operate as standalone local control devices with manual coding, then they provide reliable industrial control, but they cannot be easily managed or modified and exist in silos
Solution Approach 1:
The patent introduces a cloud-based virtualization server as an intermediary between users and PLCs. This server provides a graphical interface that abstracts the complex PLC programming and management, allowing users to configure and control PLCs remotely without needing to understand low-level programming details. The virtualization server handles the complexity of communication and code deployment, making PLC management adaptable and versatile while hiding the underlying system integration complexity.
Solution Approach 2:
The patent replaces manual PLC programming and configuration (mechanical/electrical wiring and coding) with software-based virtualization and graphical interface operations. Instead of physically connecting to PLCs and writing code, users interact through a cloud-based graphical interface that automatically generates and deploys the necessary control logic, significantly improving ease of management while reducing the perceived complexity for end users.
2Ease of operation
If PLCs are programmed manually for local control, then they provide precise control functionality, but they require significant time and expertise to program and modify
Solution Approach 1:
The patent creates a virtual copy of the PLC control environment in the cloud. Instead of directly programming physical PLCs, users work with virtual representations through a graphical interface. The virtualization server automatically translates these graphical configurations into the actual PLC code, copying the control logic from the user-friendly interface to the target PLC. This eliminates manual coding errors and significantly reduces programming time while maintaining precise control functionality.
Solution Approach 2:
The system performs preliminary actions by pre-configuring communication protocols, code compilation environments, and deployment mechanisms on the virtualization server. When a user creates a graphical configuration, the server has already prepared the necessary toolchains and pathways for automatic code generation and deployment. This preliminary setup eliminates the time-consuming steps of manual code writing, compilation, and transfer to PLCs.
3Adaptability or versatility
If PLCs operate independently without cloud connectivity, then they provide stable local control, but they lack IoT functionality and remote monitoring capabilities
Solution Approach 1:
The patent segments the PLC control system into independent functional layers: the edge layer (PLC providing stable local control), the communication layer (cloud network for data transmission), and the application layer (virtualization server providing IoT functionality). This segmentation allows each layer to operate independently with its own reliability characteristics. The PLC continues to provide stable local control without being affected by cloud connectivity issues, while the cloud layer adds IoT capabilities through the virtualization interface.
Solution Approach 2:
The system implements dynamic operation modes where PLCs can function autonomously in local mode when cloud connectivity is unavailable, maintaining stable control. When connectivity is available, the system dynamically switches to remote mode, enabling IoT functionality and cloud-based monitoring through the virtualization server. This dynamic adaptability allows the system to gain versatility without compromising the fundamental reliability of local control operations.
Data Source
AI summary
Method for creating and managing programmable logic controller (PLC) solution comprises connecting existing PLC solution to a cloud network, and connecting from a user device to a virtualization server. A graphical representation of a pin layout of a PLC is displayed on a GUI on the user device. An input comprising selection of a first pin, a sensor or an actuator configured to be coupled with the PLC via the first pin, and a parameter for the operation of the selected sensor or the selected actuator is received on the GUI. The received input is sent from the user device to the virtualization server. An executable PLC application for execution on the PLC is received on the user device. The PLC application is configured to operate and/or monitor the PLC according to the received input. The PLC application is sent to the PLC for being deployed on the PLC.