PLC Connection Adapters With Voting Across Industrial Networks
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Solution Overview
Problem
Existing PLC connection and control solutions are limited to local deployments on edge devices or local industrial computers, lacking flexibility and universality.
Innovation Solution
A system comprising an automatic converter on a third-party platform, a local adapter on a local computer, and intelligent communication interface adapters on edge devices, which utilize a voting mechanism to detect and select PLCs and edge devices for connectivity based on vote counts and states, enabling deployment on cloud-based platforms and multiple industrial networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PLC connection is based on local solutions deployed on edge devices or local industrial computers, then connection stability is improved, but deployment flexibility and universality deteriorate
Solution Approach 1:
The system divides the PLC connection functionality into separate adapter components (local adapter, intelligent communication interface adapter) that can be independently deployed on different platforms including cloud-based platforms, edge devices, or local computers. This segmentation allows the same connection solution to be flexibly deployed across multiple environments while maintaining stable PLC communication through each adapter's specialized design.
2Quantity of substance
If multiple edge devices and PLCs need to be connected and managed, then system coverage is improved, but connection management complexity deteriorates
Solution Approach 1:
The system implements a voting mechanism where edge devices and PLCs perform connectivity detection and mutual voting. Each device votes on the connectivity status of others, and the system automatically determines optimal connections based on the voting results. This feedback-based approach enables automatic management of multiple device connections without requiring complex manual configuration, as the system self-adjusts based on real-time connectivity feedback.
Solution Approach 2:
Through the voting mechanism, the system enables devices to automatically detect and determine their own connectivity status and optimal pairing. Each edge device and PLC participates in mutual detection and voting, allowing the system to autonomously manage connections without external intervention. This self-service capability significantly reduces management complexity when scaling to multiple devices.
3Adaptability or versatility
If cloud-based platforms are used for deployment, then deployment flexibility is improved, but network latency and connection reliability deteriorate
Solution Approach 1:
The intelligent communication interface adapter acts as an intermediary component that bridges cloud-based platforms and PLCs through industrial networks. It implements protocol conversion and communication adaptation, allowing cloud platforms to reliably connect to PLCs despite the inherent latency and protocol incompatibilities. The adapter handles communication protocols (such as SNAP7) and network adaptations, ensuring reliable PLC control even when deployed on cloud-based platforms with potential network latency.
Data Source
AI summary
Various embodiments of the teachings herein include a system for PLC connection. An example system may include: an automatic converter set on a third-party platform; a local adapter set on a local computer to access locally stored PLC information; and a set of intelligent communication interface adapters set on respective edge devices to access a PLC through a communication protocol connector compatible with multiple industrial networks. The automatic converter obtains information of each respective edge device through the intelligent communication interface adapter, and obtains information of each PLC through the local adapter and/or corresponding intelligent communication interface adapter. Based on a preset voting mechanism, the converter triggers the edge devices and the PLC for connectivity detection and voting, and select an individual edge device and a PLC to be connected according to the number of votes of each respective edge device and each PLC.