PLC Interface Gateway for Secure Multi-Protocol Facility Control
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Solution Overview
Problem
IoT devices often struggle to communicate and control systems controlled by programmable logic controllers (PLCs) due to vendor-specific and non-uniform PLC control protocols, which are incompatible with IoT communication protocols, limiting remote service providers' ability to automatically adjust control settings or perform software updates without manual intervention by technicians.
Innovation Solution
A facility control service that establishes an encrypted connection with PLC interfaces using a secure communication protocol, allowing for the conversion of control commands from a common secure protocol to vendor-specific PLC protocols, enabling remote control and software updates across multiple PLCs with different protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a remote service uses a common IoT communication protocol to communicate with PLCs, then the compatibility and ease of operation are improved, but the ability to control vendor-specific PLC systems is lost due to protocol incompatibility
Solution Approach 1:
The patent introduces a gateway device as an intermediary between the remote service and the PLC system. The gateway translates common IoT communication protocols into vendor-specific PLC protocols, enabling compatibility without requiring the remote service to support multiple proprietary protocols. This mediator resolves the contradiction by maintaining ease of operation while achieving adaptability to different PLC systems.
Solution Approach 2:
The gateway device dynamically changes communication parameters including protocol type, data format, and transmission mode based on the target PLC vendor and model. This parameter adaptation allows a single remote service interface to communicate effectively with diverse PLC systems, resolving the contradiction between using a common protocol and achieving vendor-specific compatibility.
2Manufacturing precision
If a technician manually re-programs PLC set-points using vendor specific interfaces, then precise control over PLC systems is achieved, but time consumption and operational complexity increase
Solution Approach 1:
The system enables self-service automated control adjustments through the gateway device that can autonomously translate and execute control commands from the remote service. Instead of requiring technicians to manually access vendor-specific interfaces, the gateway automatically handles protocol translation and command execution, maintaining precision while eliminating manual intervention and reducing time loss.
Solution Approach 2:
The patent replaces the mechanical/manual process of technician intervention with an automated electronic communication system. The gateway device electronically translates and transmits control commands automatically, substituting the physical act of manual re-programming with an automated digital process that maintains precision while dramatically reducing time consumption.
3Adaptability or versatility
If multiple vendor-specific PLC protocols are supported directly by the remote service, then compatibility with different PLC systems is improved, but device complexity and communication overhead increase
Solution Approach 1:
The patent segments the communication system into two distinct layers: a simple common protocol layer for the remote service and multiple vendor-specific protocol layers handled by the gateway. This segmentation allows the remote service to maintain simplicity while the gateway handles the complexity of multiple PLC protocols, resolving the contradiction between versatility and device complexity.
Solution Approach 2:
The gateway acts as an intermediary that consolidates multiple protocol handling capabilities into a single device. Instead of distributing complex multi-protocol support across the entire remote service system, the gateway centralizes this functionality, reducing overall system complexity while maintaining support for multiple PLC vendors through a single translation point.
Data Source
AI summary
A facility control service and programmable logic controller (PLC) interfaces enable coordination and optimization of control of various PLCs that use various PLC specific protocols. The facility control service sends control commands formatted in accordance with a secure protocol and respective PLC interfaces convert the control commands into respective PLC specific protocols. In some embodiments, a facility control service employs machine learning techniques to optimize control of PLCs at a facility. Also, in some embodiments, a facility control service coordinates deployment of PLC software to various PLCs in one or more facilities that use various PLC specific protocols.