Edge State Machine Discovery for Controller-to-MES Translation
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Solution Overview
Problem
Integration of cloud-based systems with control-level devices in industrial automation is laborious and requires expertise due to proprietary data schemas, unstructured data extraction challenges, and technology incompatibilities, complicating the integration process.
Innovation Solution
An edge-level state machine management system that discovers state machine definitions on industrial controllers and translates them into standardized information models, enabling exposure to cloud-based systems and applications, simplifying integration by using modular components and smart objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If proprietary data schemas and unstructured data extraction methods are used for integration, then system compatibility is maintained, but integration complexity and expertise requirements increase
Solution Approach 1:
The patent implements an intermediary translation layer that converts proprietary controller data schemas into standardized information models. This mediator component sits between the industrial controller and cloud-based systems, translating proprietary formats into universally accessible structures without requiring changes to the original controller or cloud system, thereby maintaining compatibility while reducing integration complexity
Solution Approach 2:
The system transforms data from proprietary formats with custom schemas into standardized information models with defined parameters and data types. This parameter transformation includes converting unstructured data into structured formats with standardized metadata, making the data compatible with common cloud platforms while simplifying the integration process
2Reliability
If proprietary data schemas are used in industrial controllers, then controller functionality is preserved, but data accessibility and discoverability for remote systems deteriorates
Solution Approach 1:
The system creates a copy of the controller's state machine data in a standardized information model format. This copy maintains the functional integrity of the original proprietary data while presenting it in an accessible, discoverable format that remote systems can read and write without affecting the original controller's operation or data integrity
3Ease of manufacture
If standardized information models are implemented for state machines, then remote system integration is simplified, but implementation complexity at the edge device increases
Solution Approach 1:
The system segments the integration functionality into distinct modular components: a discovery component that identifies state machine data, a translation component that converts to standardized models, and a publication component that exposes data to remote systems. This segmentation allows the complex translation functionality to be added to edge devices in manageable, reusable modules rather than requiring complete custom integration solutions
Data Source
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AI summary
A state machine management component that executes on an edge device within an industrial facility is capable of discovering state machines defined on industrial controllers and translating the state machine definitions to information models that allow the state machines to be discovered and utilized by remote client applications. The edge-level information models allow the client applications to render or consume the state machine data generated by the controller, graphically render the state machines, submit commands, or set values, to the controller as state machine commands via the edge device. The edge-level system thus allows client applications with no prior knowledge of the control-level state machines to discover, retrieve, and interact with state machines defined on the industrial controllers.