PLC Debugging With Synchronized Sensor and Execution Trace Data
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Solution Overview
Problem
Existing debugging solutions for programmable logic controllers (PLCs) in industrial automation are limited in synchronizing the digital program execution with the physical responses of the controlled processes, lacking a comprehensive framework to associate PLC program traces with physical sensor data, especially from modalities beyond screen capture.
Innovation Solution
A method is developed to synchronize program trace data with sensor data from multiple sources, including video cameras, by time-stamping and aligning data instances within defined capture periods, using machine learning for breakpoint generation and hardware-assisted time synchronization to present a unified debugging interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional debugging solutions trace only digital data values, then the debugging process remains simple, but the ability to correlate program execution with physical system responses is insufficient
Solution Approach 1:
The patent merges digital program trace data with physical sensor data into a unified debugging view. The system combines PLC program execution traces with sensor readings, video feeds, and other physical measurements into a single synchronized debugging interface, allowing operators to correlate digital logic with physical responses simultaneously.
Solution Approach 2:
The patent introduces a synchronization mechanism as an intermediary that aligns timestamps between digital program traces and physical sensor data. This mediator component processes and correlates data from multiple sources based on temporal relationships, enabling precise correlation without direct integration of all data streams.
2Loss of information
If multiple sensor data sources are integrated for comprehensive debugging, then the debugging insight is improved, but the data synchronization difficulty increases
Solution Approach 1:
The patent applies preliminary timestamping to all sensor data and program traces at the source before collection. Each data point is tagged with its generation time, allowing subsequent synchronization without real-time coordination between diverse data sources. This preliminary action simplifies the integration of multiple sensor types.
Solution Approach 2:
The patent creates a universal debugging interface that can handle multiple data types (sensor readings, video, program traces) through a common timestamp-based synchronization mechanism. This multi-functional approach allows the same system to integrate diverse data sources without requiring source-specific synchronization logic.
3Loss of information
If streaming video data is captured alongside sensor data, then the physical response visualization is enhanced, but the data volume and processing complexity increase
Solution Approach 1:
The patent extracts and separates video data processing from the core synchronization mechanism. Video streams are captured and timestamped independently, then overlaid onto the debugging interface without requiring the video processing to interfere with the precise timestamp-based correlation of sensor and program data. This extraction allows video to be added without compromising the core synchronization.
Data Source
AI summary
A method for synchronizing sensor data from an industrial process with program trace data from a control program executed by a programmable logic controller (PLC) controlling the industrial process. The method includes executing a control program to control industrial equipment and receiving sensor data based on physical responses from various sensors. Program trace data from the control program and sensor data is recorded during execution. The program trace data and the sensor data are time-stamped. Instances of the time-stamped program trace data and sensor data are synchronized. The synchronized data may then be replayed alongside the program trace data as the program is re-executed to allow a programmer to perform debugging.