Enterprise Communication Controller for PLC Data Acquisition
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Solution Overview
Problem
Current manufacturing systems face difficulties in direct communication between enterprise-level systems and plant floor devices due to non-standard communication protocols, leading to challenges in data acquisition and process control.
Innovation Solution
The implementation of an enterprise communication controller that plugs into the same backplane as PLCs, speaking the native protocol of the manufacturer, and running a real-time operating system to facilitate data selection, transport, and control between enterprise and plant floor levels, using software components to read/write data and communicate via standard Ethernet protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-tiered architecture with mid-level control systems is implemented, then data acquisition and process control capabilities are improved, but system complexity and difficulty of installation and maintenance increase
Solution Approach 1:
The patent extracts the mid-level control system functionality and integrates it directly into the enterprise control system. By removing the separate mid-tier layer and implementing data acquisition and process control capabilities within the existing enterprise system architecture, the solution maintains improved data acquisition while reducing overall system complexity and eliminating the need for separate mid-level control hardware and software.
Solution Approach 2:
The patent merges the functions of mid-level control systems with the enterprise control system. By combining data acquisition, process control, and enterprise-level monitoring into a unified system architecture, the solution achieves comprehensive control capabilities while reducing the number of separate system layers, thereby simplifying installation and maintenance.
2Loss of information
If direct connection between enterprise level systems and plant floor devices is established, then data accessibility is improved, but communication compatibility issues arise due to non-standard protocols
Solution Approach 1:
The patent introduces a protocol translation layer or gateway that acts as an intermediary between enterprise level systems and plant floor devices. This mediator converts non-standard plant floor protocols into standard communication protocols understood by enterprise systems, thereby achieving direct data accessibility while resolving protocol compatibility issues without requiring changes to existing plant floor equipment.
3Stability of the object's composition
If multiple layers between ERP level and controls/sensors are maintained, then system architecture stability is preserved, but direct communication between enterprise level and plant floor becomes difficult
Solution Approach 1:
The patent adds a new communication dimension or pathway that bypasses the traditional multi-layer architecture. By implementing direct communication channels at the enterprise level while maintaining the existing layered structure for other functions, the solution enables efficient data acquisition and process control without disrupting the stability of the overall system architecture.
Data Source
AI summary
A device for communicating with low level controllers and sensors located on the production floor of an enterprise directly from the top level of the enterprise. The device comprises a controller which interfaces with programmable logic controllers (PLCs) via the backplane into which the PLCs are plugged. Users are able to define triggers that specify the circumstances under which data points within the PLCs are transported to the enterprise level where they may be stored in a database or sent directly to enterprise application via one of a number of possible transfer protocols. The invention also includes a software client which allows users to set up transfer triggers and view data points on the PLCs in real time.