PLC-Cloud Control Architecture for Remote Sensor Integration
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Solution Overview
Problem
Existing control architectures for programmable logic controllers (PLCs) face challenges in managing sensors and actuators located in inaccessible places, requiring complex connections and modifications to automation programs, which limits flexibility and ease of configuration.
Innovation Solution
A control architecture that integrates a programmable logic controller with a cloud computing system, allowing data exchange using standardized protocols (MQTT or AMQP), enabling sensors and actuators to publish and subscribe data through defined storage locations, thereby decoupling the automation program from specific hardware and allowing easy configuration without modifying the program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors and actuators are connected directly to the PLC via backplane bus or dedicated communication interfaces, then the connection is stable and reliable, but the system becomes complex and difficult to configure when sensors/actuators are located in inaccessible places
Solution Approach 1:
The patent introduces a cloud computing system as an intermediary between sensors/actuators and the PLC. Remote sensors and actuators connect to the cloud platform via network, which then communicates with the PLC through standardized interfaces. This mediator approach maintains connection reliability while eliminating the need for complex direct physical connections to inaccessible devices.
Solution Approach 2:
The patent transitions from traditional physical direct connections (spatial dimension) to network-based cloud communication (virtual dimension). By moving data exchange to the cloud platform dimension, the system can access remote sensors and actuators without requiring direct physical proximity or complex wiring infrastructure.
2Adaptability or versatility
If the automation program is modified to accommodate new sensors and actuators, then the system adapts to new configurations, but the programming complexity increases and maintenance becomes difficult
Solution Approach 1:
The patent implements a universal cloud-based interface layer that handles diverse sensor and actuator types through standardized data models and communication protocols. The PLC program remains unchanged while the cloud platform adapts to different device types, providing multi-functionality without increasing program complexity.
Solution Approach 2:
The patent creates virtual representations (data models) of physical sensors and actuators in the cloud platform. These digital twins or virtual copies allow the PLC to interact with remote devices through standardized interfaces without requiring specific program modifications for each physical device variation.
3Reliability
If remote sensors and actuators are connected through dedicated communication interfaces, then the connection is reliable, but the installation becomes difficult and costly
Solution Approach 1:
The patent replaces physical communication infrastructure (cables, interfaces, direct connections) with network-based cloud communication. Instead of installing complex dedicated communication hardware to remote locations, the system uses existing network infrastructure to connect sensors and actuators to the cloud platform, significantly simplifying installation while maintaining reliability.
Data Source
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AI summary
Control architecture comprising: - at least one programmable logic controller (PLC1), - at least one cloud computing system (100), - the automation program comprising at least one predefined control module (MC1, MC2), - the cloud computing system is arranged to store first data conforming to an input data model and second data conforming to an output data model, - at least one first hardware and/or software entity arranged to publish said first data into the cloud computing system for reading by the programmable logic controller when it executes the predefined control module, - at least one second hardware and/or software entity arranged to read said second data published into the cloud computing system by the programmable logic controller when it executes said predefined control module.