Gateway PLC Network Interoperability
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Solution Overview
Problem
Existing facility systems face challenges in connecting and controlling processing machines from different industrial networks, as they require complex settings changes and specialized knowledge, making it difficult to establish mutual control between machines on different network types.
Innovation Solution
A facility system that includes gateway Programmable Logic Controllers (PLCs) connected through an upper-level network, allowing for easy integration and mutual control of processing machines across different lower-level networks, eliminating the need for individual machine settings changes and enabling communication between machines on different network types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standalone gateways are used to connect different industrial networks, then mutual control between processing machines on different networks is enabled, but the settings of PLCs must be changed which requires specialized knowledge and is difficult to perform
Solution Approach 1:
The patent introduces a gateway PLC as an intermediary device between different industrial networks. The gateway PLC includes a lower-level interface that connects to the first lower-level network and an upper-level interface that connects to the upper-level network, enabling communication between processing machines on different networks without requiring changes to the existing PLC settings on those machines.
Solution Approach 2:
The patent segments the control system into multiple levels: lower-level networks with existing PLCs for independent control, gateway PLCs for network translation and mutual control, and upper-level networks for centralized management. This segmentation allows each component to maintain its original functionality while enabling interoperability through the gateway layer.
2Adaptability or versatility
If PLCs are configured for mutual control between different networks, then interoperability is achieved, but the complexity of settings increases due to the need to modify both independent control and mutual control parameters
Solution Approach 1:
The gateway PLC serves as a mediator that handles all settings and configuration for mutual control between different networks. The lower-level interface application in the gateway PLC automatically translates between different network protocols and formats, eliminating the need to modify PLC settings on processing machines while maintaining full mutual control capability.
Solution Approach 2:
The gateway PLC creates virtual copies of I/O data and control signals between different network protocols. The lower-level interface application translates I/O data from the first lower-level network format into the upper-level network format, allowing mutual control without directly modifying the original PLC configurations.
3Adaptability or versatility
If processing machines on different networks are connected through gateways, then communication between machines is enabled, but the number of devices and network layers increases
Solution Approach 1:
The gateway PLC is designed with multi-functionality, serving as both a network gateway for protocol translation and as a control device for mutual control. The single gateway PLC performs multiple functions including I/O data translation, control signal routing, and coordination between different networks, reducing the need for separate dedicated devices for each function.
Data Source
AI summary
In a facility system, a first gateway PLC connected to first processing machines and second gateway PLCs connected to second processing machines are connected to an upper-level network. Further, the first gateway PLC and the second gateway PLCs control operation mutually associated between the first processing machines and the second processing machines on the basis of mutually associated information which is acquired from the first processing machines and the second processing machines.