Industrial Controller Configuration Using Verification Tokens
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Solution Overview
Problem
Manual updates of industrial controller units are time-consuming, costly, and prone to errors, leading to potential manufacturing downtime or machinery damage due to incorrect software or parameters being applied.
Innovation Solution
An automated configuration method using a server system and client device that sends instruction messages and verification tokens over communication networks, allowing for the automatic provision of industrial programs and parameters to industrial controller units upon successful modification verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual updates are performed by skilled users, then the industrial controller unit can be configured with control software and parameters, but the process is time-consuming and costly
Solution Approach 1:
The server system prepares and sends the verification token in advance before the actual software update process. The token is generated based on pre-validated software packages, ensuring that only authorized and verified software can be installed. This preliminary verification action eliminates the need for manual checking during the update process, reducing both time and error risk.
Solution Approach 2:
The industrial controller unit automatically verifies the software package using the verification token provided by the server system. The controller's verification unit self- validates the software integrity and authorization without requiring manual intervention from skilled operators, thereby reducing update time while maintaining reliability.
2Ease of operation
If manual updates are performed by skilled users, then the industrial controller unit can be configured, but skilled user interaction is required which increases cost
Solution Approach 1:
A server system acts as an intermediary between the software provider and the industrial controller unit. The server generates verification tokens, manages software distribution, and validates updates remotely. This intermediary layer simplifies the update process for end users while centralizing the complexity of verification and authorization management.
Solution Approach 2:
The update system is segmented into distinct functional components: a server system for token generation and software management, a verification unit in the controller for validation, and a separate software provision unit. This segmentation allows each component to specialize in its function, reducing the operational complexity for users while maintaining system sophistication.
3Reliability
If manual updates are performed, then the industrial controller unit can be re-configured, but there is risk of updating with wrong software or parameters leading to manufacturing downtime or machinery damage
Solution Approach 1:
The system applies preliminary anti-action by pre-validating software packages and generating verification tokens that encode authorization information before the update process begins. The verification unit checks this token beforehand, preventing unauthorized or incorrect software from being installed, thereby eliminating the harmful effects of wrong software application before they can occur.
Solution Approach 2:
The server system provides feedback to the industrial controller unit through the verification token, confirming whether the software package is authorized and valid. The verification unit uses this feedback to accept or reject the software update, ensuring that only correct software is applied and preventing manufacturing downtime or machinery damage from incorrect updates.
Data Source
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AI summary
A method for an automated configuration of an industrial controller unit comprises sending, from a server system, an instruction message and a verification token to a client device via a first communication network. The instruction message comprises information pertaining to a modification of an industrial controller unit, and the verification token pertains to a completed modification of the industrial controller unit. The method further comprises receiving, at the server system, a verification message pertaining to the verification token, and providing, from the server system, an industrial program and/or a parameter for an industrial program to the industrial controller unit via a second communication network, in response to receiving the verification message.