PLC Debug Log Generation Using Simulation for Untargeted Programs
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Solution Overview
Problem
Existing debugging techniques for programmable logic controllers (PLCs) are inefficient as they do not provide log information for programs that have not been pre-selected for logging, making it difficult to debug programs that are infrequently accessed or not previously targeted for logging.
Innovation Solution
A debugging assistance device that collects and generates input-output data for PLC programs by executing a simulation program that mimics the operation of the PLC, allowing for easier debugging of programs not previously logged or selected for debugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If log data collection is limited to pre-selected programs, then data collection efficiency is improved, but debugging capability for unselected programs deteriorates
Solution Approach 1:
The patent creates a copy of the PLC program in the form of simulation data that can be executed and logged without requiring actual PLC connection. This simulation copy allows debugging of any program while maintaining efficient data collection by only logging when needed.
Solution Approach 2:
The patent performs preliminary actions by collecting and storing simulation data and program information in advance. This pre-collected data can be used later for debugging without requiring real-time PLC connection, thus improving both efficiency and versatility.
2Adaptability or versatility
If simulation is used to generate log data for unselected programs, then debugging versatility is improved, but processing time increases
Solution Approach 1:
The system performs simulation and data collection in advance, storing the results for later use. This preliminary action eliminates the need for time-consuming real-time simulation during actual debugging sessions.
Solution Approach 2:
The system serves itself by automatically determining which programs need debugging and selectively generating simulation data only for those cases, rather than continuously simulating all programs.
3Adaptability or versatility
If comprehensive log data is collected for all programs, then debugging capability is improved, but data storage requirements increase
Solution Approach 1:
The patent applies different data collection strategies to different programs based on their debugging needs. Pre-selected programs get continuous logging while other programs use on-demand simulation, optimizing storage usage while maintaining debugging capability.
Solution Approach 2:
The system performs simulation and data collection partially - only for programs that need debugging and only when debugging is actually required, rather than continuously for all programs.
Data Source
AI summary
An input-output data collector collects, from a programmable logic controller, input-output data representing a log for a device in a program predetermined as a logging target program of one or more programs executable by the programmable logic controller. An input-output data generator generates, when a debugging target program is determined not to be included in the predetermined program, input-output data representing a log for a device in the debugging target program by executing a simulation program simulating an operation of the programmable logic controller.