PLC Configuration for Flexible Sensor-Actuator Subsystems
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Solution Overview
Problem
The selection of a Programmable Logic Controller (PLC) for industrial plant sub-systems is typically done early in the planning phase and involves manual upload of control programs, lacking a computer-implemented method for support.
Innovation Solution
A computer-implemented method for configuring industrial plant sub-systems, which includes storing descriptions of sensors, actuators, and PLCs in a database, generating a controller program, selecting a suitable PLC, and transferring the application to configure and connect sensors and actuators, allowing for automatic adaptation of software to the most suitable PLC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PLC selection is done manually in the planning phase, then flexibility and adaptability are limited, but the process is simple and straightforward
Solution Approach 1:
The system performs automatic PLC selection and configuration without requiring manual intervention. The computer-implemented method autonomously matches sensors and actuators with appropriate PLCs based on stored descriptions and compatibility criteria, eliminating the need for manual PLC selection and program upload processes
Solution Approach 2:
The system changes the selection criteria from manual expert judgment to automated parameter-based matching. By storing detailed descriptions of sensors, actuators, and PLCs in a database with specific parameters and compatibility rules, the system automatically determines the best PLC match based on technical specifications rather than manual planning
2Productivity
If control programs are uploaded manually to PLC instances, then customization is possible, but time consumption and labor costs increase
Solution Approach 1:
Controller programs are generated automatically based on stored descriptions of sensors, actuators, and selected PLCs. The system prepares and transfers the application program to the PLC automatically as part of the configuration process, eliminating the need for separate manual program upload steps and reducing overall configuration time
Solution Approach 2:
The manual mechanical process of program upload is replaced with an automated computer-implemented method. The system electronically generates and transfers control programs directly to PLCs through automated communication protocols, replacing manual intervention with automated software-based processes
3Reliability
If a specific PLC type is selected early in planning, then system stability is maintained, but adaptability to different PLCs is reduced
Solution Approach 1:
The system is designed to work with multiple PLC types through a universal configuration method. By storing generic descriptions of PLCs with their specific capabilities and compatibility criteria in a database, the system can automatically adapt to different PLC types while maintaining consistent configuration processes and reliability standards
Solution Approach 2:
The PLC selection becomes dynamic rather than static. Instead of fixing a specific PLC type early in planning, the system continuously evaluates compatibility between sensors, actuators, and available PLCs based on stored descriptions and current system requirements, allowing flexible selection and replacement while maintaining system stability through automated reconfiguration
Data Source
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AI summary
The invention relates to the field of industrial plants, particularly to a method for configuring a sub-system (12) of the industrial plant (10). The sub-system (12) comprises at least one sensor (20), at least one actuator (30) and at least one programmable logic controller, PLC (41, 42), The method comprises the steps of: storing a description of the at least one sensor (20) in a database (15); storing a description of the at least one actuator (30) in the database (15); storing a PLC-list (40) comprising a description of the at least one PLC (41) in the database (15); writing a controller program (50), the controller program (50) describing an action of the at least one actuator (30) caused by the at least one sensor (20); selecting, based on the database (15) and the controller program (50), a PLC (41) of the PLC-list (40), which is able to functionally connect the sensor (20) and the actuator (30); generating an application (60) for controlling the selected PLC (41), based on the selected PLC (41) and the controller program (50); and transferring the application (60) to the selected PLC (41), thus configuring and/or functionally connecting the at least one sensor (20) and the at least one actuator (30) of the sub-system (12).