Industrial Controller Loadable Modules for Continuous Program Updates
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Solution Overview
Problem
Industrial control systems face rigidity and downtime issues due to the inability to readily change control programs or add new modules without disrupting continuous operation, limiting flexibility and efficiency.
Innovation Solution
A loadable module architecture for industrial controllers allows new control program modules to be added or modified without updating firmware, using a loadable module manager to manage dependencies and admissibility criteria, and an embedded linker to bind application code to resources, enabling incremental updates and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If control programs are updated by rebuilding and transferring fully executable files, then the control system can be updated with new functionality, but the system must be taken offline resulting in costly downtime and loss of productivity
Solution Approach 1:
The control program is divided into separate loadable modules that can be independently updated and loaded without affecting the entire system. This segmentation allows individual modules to be modified while the system remains operational, eliminating the need for complete system shutdowns during updates.
Solution Approach 2:
Loadable modules are pre-compiled and prepared in advance, then stored in the controller's memory. When updates are needed, pre-validated module versions can be quickly swapped in without requiring on-the-fly compilation or system downtime, enabling seamless updates while maintaining continuous operation.
2Adaptability or versatility
If control programs are updated by rebuilding and transferring executable files, then new functionality can be added, but the update process is time-consuming and requires taking the system offline
Solution Approach 1:
The control program is divided into separate loadable modules that can be independently updated and loaded without affecting the entire system. This segmentation allows individual modules to be modified while the system remains operational, eliminating the need for complete system shutdowns during updates.
Solution Approach 2:
Loadable modules are pre-compiled and prepared in advance, then stored in the controller's memory. When updates are needed, pre-validated module versions can be quickly swapped in without requiring on-the-fly compilation or system downtime, enabling seamless updates while maintaining continuous operation.
3Adaptability or versatility
If control programs are updated by rebuilding and transferring executable files, then the control system can be modified, but the process lacks flexibility in moving modules between controllers
Solution Approach 1:
Loadable modules are designed with universal interfaces and standardized resource connection protocols that allow the same module to be deployed across different controllers and controlled processes. This universality enables modules to be freely moved and reused without breaking resource connections, simplifying reconfiguration while maintaining adaptability.
4Productivity
If control programs are updated by rebuilding and transferring executable files, then the system can be updated, but the design process becomes more complex and less efficient
Solution Approach 1:
The control program is divided into separate loadable modules that can be independently updated and loaded without affecting the entire system. This segmentation allows individual modules to be modified while the system remains operational, eliminating the need for complete system shutdowns during updates.
Solution Approach 2:
Loadable modules are designed with universal interfaces and standardized resource connection protocols that allow the same module to be deployed across different controllers and controlled processes. This universality enables modules to be freely moved and reused without breaking resource connections, simplifying reconfiguration while maintaining adaptability.
Data Source
AI summary
Systems are provided for a “loadable module” architecture for industrial controllers in which new control program modules which provide updated functions or features may be loaded to extend or modify the underlying operating system and/or other services without updating the firmware and without disrupting or otherwise compromising the ability of the industrial controller to maintain continuous control over the controlled process. Control program modules and libraries may be delivered to the industrial controller in object code format and an embedded linker in the industrial controller may be used to efficiently create fully linked and executable files locally. Loadable libraries may be provided to the industrial controller during runtime to extend functionality and/or provide desired fixes. As a result, a system is provided that is more efficient and that enables significant flexibility in adding new capabilities.