Controller Introspection for Mapping Subtended IoT Devices
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Solution Overview
Problem
Automated industrial and commercial environments often have complex configurations with IoT devices controlled by PLCs, where the exact logic is not accessible due to outdated configurations or lack of documentation, making it difficult to understand relationships between controllers and subtended devices, requiring manual reverse engineering which is time-consuming.
Innovation Solution
A platform and method that automatically identifies and maps data sources and controllers using introspection directives, communication mechanisms, and data storage systems to quickly discover and present relationships between controllers and subtended devices, utilizing passive and active discovery methods to access configuration information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If manual reverse engineering is used to understand PLC logic and device relationships, then complete understanding of the automation environment is achieved, but the process takes weeks to years depending on size and complexity
Solution Approach 1:
The patent replaces manual reverse engineering (mechanical human effort) with automated introspection systems that use software agents to query PLCs and extract logic and device relationships automatically, reducing the process from weeks/months to hours or minutes while maintaining complete understanding of the automation environment
Solution Approach 2:
The PLC system performs self-introspection by executing introspection routines that automatically query its own memory structures, I/O mappings, and logic configurations, allowing the system to document itself without external manual intervention, thereby eliminating the time-consuming manual reverse engineering process
2Reliability
If third-party integrators configure PLC logic with custom logic, then automation environments perform flawlessly, but the logic becomes inaccessible after the integrator is no longer in business or never provided credentials
Solution Approach 1:
The patent implements automated introspection and documentation generation that creates complete records of PLC logic, device relationships, and configuration data while the system is still operational and accessible, storing this information in searchable databases and digital twins for future reference, thereby preserving access to the logic before integrators become unavailable
Solution Approach 2:
The system creates digital copies of the PLC logic and configuration through automated introspection, generating digital twins and documentation that replicate the exact behavior and structure of the original PLC program, allowing future maintenance and understanding without requiring access to the original integrator or physical PLC
3Ease of operation
If controllers map IoT devices through southbound control buses and GPIO ports to northbound control buses, then device control is achieved, but understanding subtended devices requires manual intervention
Solution Approach 1:
The patent implements automated discovery systems that query controllers for their configured I/O mappings and device relationships, using feedback loops to automatically trace southbound control bus connections through GPIO ports to northbound control buses, thereby automatically identifying subtended devices without manual intervention while maintaining the existing control architecture
Data Source
AI summary
Described are platforms, systems, and methods to discover subtended devices through introspection of executive or supervisory controllers. The platforms, systems, and methods maintain a plurality of introspection directives, each introspection directive comprising a sequence of instructions specific to a communications protocol, the sequence of instructions comprising instructions to send at least one command to at least one controller associated with an automation environment in accordance with the communications protocol, instructions to receive a response to the at least one command, and instructions to parse the response; identify an appropriate introspection directive for the at least one controller; and execute the sequence of instructions with respect to the at least one controller to perform operations comprising: sending at least one command to at least one controller; receiving a response; and parsing the response.