Industrial Controller Code Conversion via I/O Behavior Modeling
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Solution Overview
Problem
Migrating from obsolete industrial controller systems is challenging due to unreadable or inaccessible logic code, lack of documentation, and the need for manual re-development, which is time-consuming and costly.
Innovation Solution
A system that collects and analyzes input and output data from the controller using artificial intelligence and machine learning to generate a functional design specification and application code, incorporating standard code libraries for readability and validation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual re-development of control logic is performed for obsolete controllers, then the control system can be migrated to newer hardware, but the process is time-consuming and costly
Solution Approach 1:
The system creates a digital twin or virtual model of the obsolete controller by monitoring its input and output states during normal operation. This virtual model captures the control logic behavior without requiring physical access to the controller's internal code, enabling the logic to be replicated on new controller hardware automatically
Solution Approach 2:
A virtual controller model serves as an intermediary between the obsolete physical controller and the new controller hardware. This intermediary captures the control logic through I/O monitoring and translates it to new instruction sets, eliminating the need for manual reverse-engineering of the original controller code
2Loss of information
If control logic is accessed from obsolete controllers, then the original programming intent can be understood, but the logic code is often unreadable or inaccessible
Solution Approach 1:
Instead of attempting to read the inaccessible internal code, the system creates a functional copy by monitoring the external behavior (I/O states) of the controller. This behavioral copy captures the essential control logic without requiring access to the original proprietary or corrupted code
Solution Approach 2:
Rather than trying to extract logic from the controller's internal memory (traditional approach), the system inverts the approach by inferring the control logic from the controller's external input and output behavior. This reverse engineering through observation bypasses the inaccessibility of the original code
3Adaptability or versatility
If control logic is manually re-developed without documentation, then migration can proceed, but the process requires significant human effort and expertise
Solution Approach 1:
The system performs automatic self-service by monitoring the controller's I/O states and generating the virtual model without human intervention. The automated analysis and code generation processes eliminate the need for manual reverse-engineering efforts and specialized expertise
Solution Approach 2:
The virtual controller model acts as an intermediary that automatically translates the behavioral data into new control code for different hardware platforms. This intermediary handles the complexity of logic translation between different instruction sets and hardware architectures without requiring human experts
Data Source
AI summary
Techniques for converting an initial control program code version to a new control program code version are disclosed herein. In at least one implementation, input and output states of an industrial controller are monitored while the industrial controller executes the initial control program code version to operate a machine system and functional design specification for the industrial controller is generated. An instruction set of the industrial controller is converted into a new instruction set for a new industrial controller, and one or more equivalent instructions in the new instruction set that are equivalent to instructions in the instruction set of the industrial controller are identified. The new control program code version is generated based on at least the functional design specification and the one or more equivalent instructions in the new instruction set that are equivalent to the instructions in the instruction set of the industrial controller.