Gateway Middleware for Legacy System IT Integration
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Solution Overview
Problem
Many existing machines and production plants, particularly those in operation for 10 to 40 years, lack network capabilities and thus cannot be easily connected to IT systems like the internet or intranets, necessitating a method for retrospective connection of data source systems to IT systems.
Innovation Solution
A gateway with real-time and non-real-time capable middleware on a common operating system, utilizing hardware and software interfaces to connect data source systems to IT systems, allowing for web-based configuration and modular extensibility without the need for additional programming, using existing processing units like PLCs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing machines and production plants (operating for 10 to 40 years) are connected to IT systems, then network capability and data communication are improved, but device complexity and integration difficulty increase due to legacy architecture
Solution Approach 1:
The patent introduces a gateway as an intermediary device that mediates between legacy data source systems and modern IT systems. The gateway contains a non-real-time capable middleware that communicates with legacy systems using traditional protocols while simultaneously providing web-based interfaces and data sources for cloud connectivity, thereby enabling network capability without directly modifying complex legacy systems.
Solution Approach 2:
The patent segments the system into distinct functional layers: a real-time capable middleware layer for legacy system integration, a non-real-time capable middleware layer for web-based communication, and a cloud platform layer for data processing. This segmentation allows each layer to be optimized independently, reducing overall integration complexity while enabling network capability.
2Adaptability or versatility
If retrospective connection of legacy systems to IT systems is implemented, then internet capability is improved, but additional hardware and programming requirements increase system complexity
Solution Approach 1:
The gateway is designed as a universal platform that can connect to multiple types of legacy systems through standardized interfaces while providing consistent web-based output. The non-real-time capable middleware implements universal communication protocols (HTTP, HTTPS, OPC UA) that work across different legacy system types, eliminating the need for system-specific programming and reducing hardware requirements.
Solution Approach 2:
The system enables self-service configuration through web-based interfaces where operators can configure and monitor legacy system connections without requiring programming expertise. The gateway automatically manages data extraction, transformation, and communication protocols, allowing legacy systems to gain internet capability through simple configuration rather than complex programming.
3Reliability
If real-time capable middleware is used for legacy system integration, then processing reliability is improved, but system resource consumption increases
Solution Approach 1:
The patent implements dynamic task scheduling where the real-time capable middleware processes time-critical data with high priority while the non-real-time capable middleware handles less time-sensitive web communications with lower priority. This dynamic allocation ensures processing reliability for critical functions while minimizing overall system resource consumption by not dedicating full real-time resources to all tasks.
Solution Approach 2:
The system applies partial real-time processing only where necessary for legacy system reliability requirements, rather than implementing full real-time processing across all functions. The non-real-time capable middleware handles web-based communications with relaxed timing constraints, reducing overall resource consumption while maintaining sufficient reliability for the specific application needs.
Data Source
AI summary
A gateway and method are disclosed for connecting a data source system to an IT system, having real-time capable middleware and non-real-time capable middleware on a common operating system. An application for communicating via a network protocol is executed on the non-real-time capable middleware which comprises a framework, at least one hardware interface via which the data source system is connected to the real-time capable middleware, at least one hardware interface via which the IT system is connected to the non-real-time capable middleware, and a software interface configured to allow communication between the real-time capable middleware and the non-real-time capable middleware. The gateway is configured to provide, via the framework, predefined software interfaces for individual components of the data source system, which components can be connected to the real-time capable middleware, or for components of the IT system.