PLC Execution Environment Selective Update via Segmentation
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Solution Overview
Problem
In industrial automation, updating the execution environment of programmable logic controllers (PLCs) is costly and disruptive, as manufacturers often need to replace entire controllers, leading to increased support costs and production downtime.
Innovation Solution
A method and system for efficiently updating the execution environment of PLCs by reading controller type and version information, determining the necessary updates, and applying them selectively, using a programming tool connected to a server that stores update information and software.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire controller is replaced to update the execution environment, then the execution environment can be updated completely, but the support cost increases and manufacturing downtime increases
Solution Approach 1:
The execution environment is segmented into separate updateable components (system programs, library programs, configuration data) that can be updated independently without replacing the entire controller. The programming tool reads controller type and version information, determines necessary updates, and applies them selectively to specific parts of the execution environment.
Solution Approach 2:
The update capability is extracted as a separate function performed by the programming tool, which reads the current execution environment state, determines required updates based on version information, and applies only the necessary changes without requiring full controller replacement.
2Reliability
If the entire controller is replaced to update the execution environment, then the execution environment can be updated completely, but the support cost increases
Solution Approach 1:
The execution environment is segmented into separate updateable components (system programs, library programs, configuration data) that can be updated independently. This segmentation allows selective updating of only the necessary parts, reducing support costs by avoiding full controller replacements.
Solution Approach 2:
The update functionality is extracted as a separate capability of the programming tool, which intelligently determines and applies only the necessary updates based on controller type and version information, thereby reducing support costs.
3Loss of time
If selective updating is implemented, then support costs and downtime are reduced, but the complexity of the update process increases
Solution Approach 1:
The programming tool performs self-service by automatically reading controller type and version information, determining necessary updates, and applying them without requiring complex manual intervention. The system autonomously manages the selective update process, reducing perceived complexity for the user.
Solution Approach 2:
The system uses feedback from reading controller type and version information to intelligently determine which updates are necessary. This feedback mechanism allows the programming tool to selectively apply only the required updates, simplifying the process despite the underlying complexity.
Data Source
AI summary
A system and method for performing software maintenance of a programmable logic controller are provided. The system includes a programming tool and a controller. The programming tool is operable to update an execution environment of the controller and includes a controller type determination unit for reading a controller type of the controller and version information of an operating system thereof, an update information determination unit for reading update information corresponding to the controller type and the version information, an update area determination unit for determining a part of the execution environment to be updated based on the update information, and an updating unit for updating the determined part of the execution environment.