Cloud PLC Reconfiguration for Interoperable Industrial Automation
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Solution Overview
Problem
Current industrial automation systems face challenges with interoperability, security issues, high costs, and vendor-specific architectures, leading to inefficiencies and vulnerabilities, particularly in reconfiguring and integrating with modern company software systems.
Innovation Solution
A cloud-based system for closed-loop reconfiguration of industrial automation systems, utilizing a PLC Twin service that allows for compile-time modification of controller programs and configurations, enabling integration with company core software systems and supporting microservices architecture, with features like IDEaaS, code versioning, and secure connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If proprietary technology and vertical system integration are used in industrial automation, then within-stack compatibility is guaranteed, but interoperability across different automation technology platforms decreases
Solution Approach 1:
The patent implements a universal communication interface that enables different automation technology platforms to interoperate through standardized protocols. The system allows proprietary devices to communicate across vendor boundaries by translating proprietary protocols into universal communication standards, thereby achieving multi-functionality and cross-platform compatibility without sacrificing within-stack compatibility
Solution Approach 2:
The patent introduces an intermediary communication layer that acts as a mediator between proprietary automation devices and external systems. This intermediary translates proprietary protocols into standardized communication protocols, enabling interoperability across different technology platforms while maintaining the integrity of original vendor-specific implementations
2Adaptability or versatility
If hardware and software are tightly coupled in PLC runtime systems, then control functionality is integrated, but system reconfiguration flexibility decreases
Solution Approach 1:
The patent segments the tightly coupled hardware-software architecture into separate modular components. The control system is divided into independent hardware modules and software modules that can be configured and reconfigured independently, allowing flexible system reconfiguration without requiring changes to the underlying hardware architecture
Solution Approach 2:
The patent implements dynamic reconfiguration capabilities that allow the control system to adapt its software configuration in real-time without hardware changes. The system supports runtime modification of control logic and parameters, enabling flexible adaptation to changing production requirements while maintaining stable hardware infrastructure
3Adaptability or versatility
If PLC code editing systems are kept local and require physical proximity to PLC devices, then programming control is straightforward, but system integration with cloud-based software systems decreases
Solution Approach 1:
The patent introduces a cloud-based intermediary interface that connects local PLC programming systems with cloud-based software platforms. This intermediary enables remote access to PLC code editing and system configuration through standardized communication protocols, allowing engineers to program and configure controllers from remote locations while maintaining full control functionality
Solution Approach 2:
The patent replaces the mechanical requirement of physical proximity to PLC devices with electronic/cloud-based access mechanisms. Engineers can access and modify PLC code through cloud-based interfaces and remote communication protocols, eliminating the need for physical presence at the control cabinet while maintaining programming capabilities
4Productivity
If vendor-specific hardware architectures and ASICs are used, then specialized functionality is achieved, but lead times for automation equipment increase
Solution Approach 1:
The patent uses software-based virtualization to create virtual copies of specialized hardware functionality. Instead of requiring physical ASICs for each specialized function, the system uses software-defined controllers that can replicate specialized hardware behavior through firmware and software implementations, significantly reducing hardware lead times while maintaining specialized functionality
5Reliability
If software and hardware are integrated in a single PLC, then deterministic runtime is achieved, but cost of compute increases
Solution Approach 1:
The patent segments the integrated PLC architecture into separate hardware and software components that can be optimized independently. Deterministic runtime-critical functions are implemented in dedicated hardware or real-time operating systems, while non-critical functions use standard computing resources, thereby achieving deterministic performance without requiring expensive integrated PLC hardware for all functions
Data Source
AI summary
A method for closed loop reconfiguration of an industrial automation system includes receiving, at a cloud computing system, via a network, sensor data associated with a subsystem of the industrial automation system controlled by a controller of the industrial automation system, generating, by the cloud computing system, a modified controller program and/or a modified controller configuration, based on analyzing the received sensor data, 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. The modified controller program defines run time operation of the controller.