Industrial Controller Logic Emulation for Legacy Code Migration

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Solution Overview

Problem

Old industrial controller systems often have unreadable or inaccessible logic code, making it difficult and costly to migrate to new systems, as developers must manually observe and recreate the machine's functionality.

Innovation Solution

A system that monitors and analyzes the input and output states of an industrial controller using AI and machine learning to generate a functional design specification and application code, allowing for the emulation of the controller's functionality on newer systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual observation and recreation of machine functionality is used to migrate from old industrial controller systems, then the migration can be completed, but the process is time-consuming and costly

Engineering Contradiction:

Improvemigration accuracyVSAvoidmigration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system automatically copies the control logic from the legacy controller by monitoring its input and output states, then generates equivalent code for the new controller platform. This automated copying process replaces manual observation and recreation, significantly reducing migration time while maintaining accuracy through systematic data collection and analysis.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the manual mechanical process of observing and recreating control logic with an automated electronic system that monitors controller states and generates code through software analysis. This substitution of manual operations with automated electronic monitoring and processing reduces both time and human effort while improving consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual observation and recreation of machine functionality is used to migrate from old industrial controller systems, then the migration can be completed, but the process is costly

Engineering Contradiction:

Improvemigration accuracyVSAvoidmigration cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #26Copying

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If the logic code of old industrial controller systems is accessed manually, then the code can be read, but the code is often unreadable or inaccessible

Engineering Contradiction:

Improvecode accessibilityVSAvoidcode readability

Core Design Contradiction:

Loss of informationVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #26Copying

Solution Approach 2:

Instead of trying to read and understand the existing unreadable code, the system inverts the approach by directly monitoring the controller's operational states and generating new code that replicates the observed behavior. This inversion bypasses the readability problem entirely by working from observable behavior rather than attempting to interpret existing code.

Inventive Principle:

Principle #13The other way round (Inversion)

4Productivity

If automated code generation is implemented, then migration time is reduced, but the system complexity increases

Engineering Contradiction:

Improvemigration speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system introduces an automated code generation tool as an intermediary between the legacy controller and the new controller platform. This intermediary automatically monitors, analyzes, and translates control logic, reducing migration time while managing complexity through specialized software that handles the complex tasks of state monitoring, analysis, and code generation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Inventive Principle:

Principle #26Copying

Data Source

PatentUS10948883B2Machine logic characterization, modeling, and code generation

Publication Date: 2021.03.16 ROCKWELL AUTOMATION TECH INC

AI summary

Techniques to facilitate generation of controller application code that emulates functionality of an industrial controller are disclosed herein. In at least one implementation, a computing system interfaces with the industrial controller and monitors input and output states of the industrial controller while the industrial controller operates a machine system. The input and output states of the industrial controller used to operate the machine system are analyzed to generate a functional design specification for the industrial controller. The controller application code that emulates the functionality of the industrial controller is generated based on the functional design specification.