Keyword-Based PLC Programming for Consistent Control Logic
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Solution Overview
Problem
The manual programming of Programmable Logic Controllers (PLCs) is time-consuming, prone to human error, and difficult to modify or expand, especially when the original programmer is no longer available, due to lack of internal and cross-program consistency in structure and terminology.
Innovation Solution
A system and method for programming PLCs using keywords, which involves receiving a device list and a cause-and-effect list, applying a control algorithm to assign controls using a keyword database, generating control logic, and outputting the PLC program as a file, allowing for reduced time and increased efficiency in programming and future modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PLC programs are created manually by skilled individuals, then the programs can be customized to specific needs, but the programming process becomes time-consuming and prone to human error
Solution Approach 1:
The system performs preliminary actions by automatically generating device lists, cause and effect lists, and control logic templates before the actual programming process. This pre-processing of information structures enables rapid program creation while maintaining customization, as the automated system prepares the foundational elements that skilled programmers would otherwise create manually from scratch
Solution Approach 2:
The patent introduces an intermediary automated programming system that acts as a mediator between the programmer's intent and the final PLC code. This intermediary system uses algorithms to translate high-level requirements into structured control logic, reducing direct manual coding while preserving customization capabilities through configurable parameters and templates
2Adaptability or versatility
If PLC programs are created manually, then specific control needs can be met, but validation becomes intensive and error risk increases
Solution Approach 1:
The system implements feedback mechanisms where the automated programming algorithm validates generated control logic against the cause and effect list and device specifications. This automated validation provides immediate feedback on program correctness, reducing errors by systematically checking consistency between requirements and generated code before finalization
Solution Approach 2:
The system performs preliminary validation and consistency checks during the automated program generation process, before the program is finalized. By validating the control logic against the cause and effect relationships and device lists in advance, the system catches errors early, reducing the intensive validation effort needed afterward and lowering overall error rates
3Adaptability or versatility
If custom PLC programs are created manually, then specific processes can be controlled, but future modification becomes difficult when the original programmer is unavailable
Solution Approach 1:
The patent segments the PLC program into distinct, organized components including device lists, cause and effect lists, control logic templates, and keyword-based control definitions. This segmentation creates a modular structure where each component can be independently modified, making maintenance easier when the original programmer is unavailable, as changes can be made to specific segments without affecting the entire program
Solution Approach 2:
The system creates universal, standardized control logic templates and keywords that can be applied across different PLC programs and processes. This universality ensures that programs follow consistent structures and naming conventions, making them easier to understand and modify by different programmers, as the same standardized components can be reused and adapted to various control scenarios
Data Source
AI summary
The present invention relates to generally to programmable logic controllers (PLCs), and more particularly to a system and method to enables a user to accelerate the generation of PLC programs. The system includes a set of specific keywords and an internal algorithm that in combination with the industrial process information provided by the user, creates a methodology for PLC program generation, which is flexible enough to adapt to the user, PLC programming strategies, and other standards and practices.