Cloud PLC Twin Reconfiguration for Industrial Controller Interoperability
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Solution Overview
Problem
Existing industrial automation systems face interoperability issues, high costs, security vulnerabilities, and inefficiencies due to tight coupling of hardware and software, limiting integration with modern company software systems and leading to long lead times and supply chain disruptions.
Innovation Solution
A cloud-based system for configuring and optimizing industrial automation controllers through a PLC Twin service, allowing modification of controller programs and configurations at compile time, enabling integration with company core software systems and supporting closed-loop reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardware and software are tightly coupled in PLC runtime systems, then control functionality is integrated, but interoperability decreases and system complexity increases
Solution Approach 1:
The patent segments the PLC system into separate hardware and software components. The controller hardware operates independently while the control software can be updated and modified separately through cloud-based services, enabling both integrated control functionality and improved interoperability.
Solution Approach 2:
The patent introduces a cloud-based intermediary service that acts as a mediator between the PLC controller and external systems. This intermediary enables communication and data exchange without requiring tight coupling, thus maintaining control functionality while improving interoperability across different platforms.
2Stability of the object's composition
If proprietary technology is used for vertical system integration, then within-stack compatibility is guaranteed, but costs increase and security issues arise
Solution Approach 1:
The patent implements a universal cloud-based service platform that can interface with multiple different PLC vendors and control systems through standardized protocols. This multi-functional approach maintains within-stack compatibility while reducing dependency on proprietary technologies, thereby lowering costs and improving security.
Solution Approach 2:
The patent creates virtual copies or representations of control system data and configurations in the cloud, allowing access and modification without directly interacting with the physical PLC hardware. This copying mechanism maintains compatibility while reducing security risks and costs associated with direct hardware access.
3Ease of operation
If PLC code editing systems are kept local, then control code can be edited, but physical proximity to PLC device is required and productivity decreases
Solution Approach 1:
The patent moves the code editing capability from the physical dimension (local PC next to PLC) to the network dimension (cloud-based access). Engineers can edit control code from any location with network connectivity, maintaining ease of operation while dramatically improving productivity by eliminating the need for physical proximity to the PLC device.
4Adaptability or versatility
If cloud-based services are used for PLC configuration, then integration with company software systems is enabled, but network dependency increases
Solution Approach 1:
The patent implements preliminary action by allowing configuration data and control programs to be downloaded to local devices or cached before network connectivity is needed. This enables the PLC to continue operating with pre-loaded configurations even when network connectivity is interrupted, thus enabling cloud-based integration while mitigating network dependency risks.
Data Source
AI summary
A method for configuring a controller of an industrial automation system via a network includes obtaining, by a cloud computing system, a controller configuration and a controller program. The cloud computing system generates, 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. The cloud computing system also generates a modified controller program and 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. The cloud computing system provides, via the network, the modified controller program and the modified controller configuration to the controller of the industrial automation system.