Industrial Controller Cloud Integration for Remote Configuration
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Solution Overview
Problem
Industrial controller systems are complex and cumbersome, making configuration and data management time-consuming and difficult for non-technical users, especially in real-time or near real-time scenarios, due to multiple layers of technology and lack of user-friendly interfaces.
Innovation Solution
The introduction of industrial controller devices with built-in wireless and wired communications, data storage, and configuration capabilities that allow for remote management via a cloud-based server, providing interactive graphical user interfaces for centralized monitoring and configuration, enabling efficient data collection, control, and analytics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple layers of technology devices are used in industrial controller systems, then functionality and control capability are improved, but system complexity and difficulty of configuration increase
Solution Approach 1:
The patent combines multiple technology layers (sensors, controllers, HMI devices, databases) into an integrated system where a single controller device can perform sensing, control, data storage, and communication functions. This merging reduces the number of separate devices needed while maintaining full functionality, directly addressing the contradiction between versatility and complexity.
Solution Approach 2:
The controller device is designed as a universal platform that can perform multiple functions including data acquisition from sensors, processing control logic, storing data locally, communicating wirelessly or wired, and providing HMI interfaces. This multi-functionality allows a single device to replace multiple specialized devices, reducing system complexity while maintaining adaptability.
2Manufacturing precision
If manual interaction with individual controller devices is required for configuration, then device-level control precision is improved, but time consumption and labor requirements increase
Solution Approach 1:
The system allows configuration parameters to be pre-defined and stored in a database before deployment. When the controller device is deployed, it automatically retrieves and applies these pre-configured parameters, eliminating the need for manual configuration at the device level while maintaining precise control settings.
Solution Approach 2:
The HMI device provides real-time feedback on controller device status and configuration parameters. This allows operators to monitor and adjust settings remotely with immediate visibility of the effects, reducing the need for repeated manual interactions and on-site adjustments, thereby reducing configuration time while maintaining precision.
3Measurement precision
If data is gathered from individual controller devices manually, then data accuracy is improved, but real-time analysis capability deteriorates
Solution Approach 1:
The system implements continuous automatic data collection from sensors and controller devices, with data being continuously transmitted to and stored in the database. This continuous data flow enables real-time analysis without interrupting the measurement process, maintaining data accuracy while enabling immediate analysis of incoming data streams.
Solution Approach 2:
The database acts as an intermediary between controller devices and analysis tools. It continuously receives and stores data from multiple devices in a standardized format, allowing analysis software to query and process data in real-time without direct connection to individual devices, thus maintaining data integrity while enabling rapid analysis.
4Reliability
If firmware updates and settings adjustments require physical access to devices, then device security is improved, but ease of maintenance and updates deteriorates
Solution Approach 1:
The controller device is designed to automatically receive and apply firmware updates and configuration changes remotely through wireless or wired connections. The device maintains security through authenticated communication protocols while allowing remote maintenance operations, eliminating the need for physical access while preserving both security and ease of maintenance.
Data Source
AI summary
Controller devices may be configured to automatically connect to a remote management server (e.g., a “cloud”-based management server), and may offload received data and analyses to the remote management server via wired or wireless communications. The controller devices may further communicate with the management server, user computing devices, and/or human machine interface devices, e.g., to provide remote access to the controller device, provide real-time information from the controller device, receive configurations/updates, provide interactive graphical user interfaces, and/or the like.