Industrial Controller Firmware Extensions for Faster Function Updates
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Solution Overview
Problem
Industrial controllers, such as PLCs, face long wait times for firmware updates, which can lead to delayed addition of required or requested functionality, especially in urgent situations, due to infrequent updates and the lack of time to incorporate all necessary changes between updates.
Innovation Solution
The development and deployment of loadable embedded software extensions that expand controller functionality beyond the base firmware, allowing for the addition of new features without full firmware updates, through a framework that includes a design environment, extension repository, deployment interface, and execution environment, enabling faster addressing of customer needs and enhancing security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If firmware updates are performed periodically to add functionality, then the controller firmware is updated with new features, but there is a long wait time before updates are released and functionality is added
Solution Approach 1:
The patent segments the firmware update process by introducing a separate, loadable extension module that can be independently developed, tested, and deployed without requiring a full firmware update cycle. This extension module contains specific functionality that can be loaded dynamically into the controller's memory space, allowing functionality to be added without waiting for periodic firmware releases.
Solution Approach 2:
The extension module is developed and prepared in advance outside the controller, allowing functionality to be created and validated before deployment. The extension includes all necessary components (code, data, configuration) pre-packaged and ready to be loaded, eliminating the need to wait for firmware update cycles to add new functionality.
2Productivity
If there is not enough time to add all required functionality between firmware updates, then functionality is delayed, but this results in even more time passing before functionality is added
Solution Approach 1:
The patent divides the controller functionality into core firmware and separable extension modules. This segmentation allows small, specific functionality to be developed and deployed as independent extensions without waiting for comprehensive firmware updates, significantly accelerating the delivery of individual features and capabilities.
Solution Approach 2:
The extension module acts as an intermediary between the controller firmware and external functionality requirements. It provides a mechanism to bridge the gap between available firmware capabilities and required functionality by loading additional code and data into the controller's memory, enabling rapid response to functionality needs without the constraints of firmware update schedules.
3Loss of time
If extensions are deployed independently of full firmware updates, then wait times are reduced and security is enhanced, but the system complexity increases
Solution Approach 1:
The extension module is designed with a universal structure that can be deployed independently of the specific firmware version, using standardized interfaces and memory loading mechanisms. This multi-functionality allows the same extension deployment process to work across different controller configurations and firmware versions, reducing the need for complex version-specific deployment logic.
Solution Approach 2:
The extension module is self-contained with all necessary components (executable code, data structures, configuration parameters) packaged together, allowing it to be loaded and executed independently without requiring complex integration processes or modifications to the core firmware. The extension manages its own initialization and execution, reducing the burden on the host system.
Data Source
AI summary
Various embodiments of the present technology generally relate to industrial controller firmware. More specifically, some embodiments relate to systems and methods for developing, deploying, and executing loadable embedded software extensions that expand controller functionality beyond that of what is available in a controller's base firmware. Systems and methods described herein provide for a firmware extension development environment, a firmware extension repository, a firmware extension deployment interface, and various firmware extension executions models. During execution of a control program within an industrial controller, when directed by the logic of the control program to perform an external function, industrial controller firmware may call an external component provided by an extension developed in accordance with the present disclosure to perform the external function.