Industrial Controller Debugging via Virtual Model Linking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Debugging complex control programs for industrial controllers is time-consuming and often requires interrupting the controlled process, which can be unsafe, especially in automated installations where uncontrolled movements need to be avoided.
Innovation Solution
A method and device for programming industrial controllers that utilize a debugging tool to establish a reverse relationship between machine code and high-level control instructions, allowing real-time execution of machine code programs without breakpoints or step-by-step modes, linking high-level control instructions to real system states through sensor data, facilitating efficient debugging by correlating control instructions with their effects on the installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional debugging tools with breakpoints and step-by-step modes are used, then programming errors can be detected, but the controlled process must be interrupted which can be unsafe and time-consuming
Solution Approach 1:
The patent creates a virtual model that copies the control program's execution behavior and links it to the physical system's actual state through sensor data. This virtual copy allows debugging without interrupting the real controlled process, as all observations and analyses occur in the virtual model while the physical system continues operating normally.
Solution Approach 2:
The patent introduces a virtual model as an intermediary between the debugger and the physical controlled system. The virtual model receives control instructions and sensor data, then presents this information to the debugger in a way that doesn't require interrupting the actual controlled process, thus maintaining safety while enabling debugging.
2Ease of operation
If complex control programs are debugged using conventional methods, then errors can be identified, but the process requires interrupting execution which reduces productivity
Solution Approach 1:
By creating a virtual model that replicates the control program's execution, the system allows continuous observation of program behavior without stopping the controlled process. The virtual model executes alongside the real system, enabling error identification while maintaining full productivity.
Solution Approach 2:
The system continuously feeds sensor data from the physical system into the virtual model, which then provides feedback about the correspondence between virtual and actual system states. This feedback mechanism enables real-time error detection without interrupting the controlled process, thereby maintaining productivity.
3Difficulty of detecting and measuring
If the controlled process is interrupted for debugging, then detailed analysis of control instructions is possible, but uncontrolled movements may occur creating safety hazards
Solution Approach 1:
The virtual model copies the control program's execution and links it to the actual system state through sensor data. This allows detailed analysis of control instructions in the virtual model without interrupting the physical system, eliminating the safety hazard of uncontrolled movements while maintaining full analysis capability.
Solution Approach 2:
The virtual model acts as an intermediary that provides the detailed control instruction analysis capability without requiring interruption of the physical controlled process. All analytical operations occur in the virtual model, which safely mediates between the debugger and the running physical system.
Data Source
AI summary
An installation comprises at least one sensor for providing sensor data representing a real system state of the installation and at least one actuator for acting on the real system state. A controller for controlling the installation comprises a data memory for storing the sensor data and a program memory for storing a machine code program. A programming tool for programming the controller includes a program editor, a debugging tool and a compiler. A machine code program is executed on the controller while the debugging tool is activated, and the debugging tool determines a reverse relationship between the machine code running on the controller and at least one high level control instruction shown in the program editor, thereby linking at least one high level control instruction to a real system state during the execution of the machine code program.