PLC Ladder Logic Generation Using Configuration-Driven Templates
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Solution Overview
Problem
Creating ladder logic programming for programmable logic controllers (PLCs) is a cumbersome and tedious process, even for relatively small industrial applications.
Innovation Solution
A computer-implemented method and system that automatically generates PLC ladder logic by receiving configuration data through a table-based interface, determining corresponding templates, and creating PLC logic using a repository of ladder logic templates, add-on instructions, and defined data types to populate the templates with configuration data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual ladder logic programming is used, then PLC logic can be created with full customization, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The system performs preliminary actions by pre-defining common PLC logic patterns as reusable templates before actual programming is needed. These templates contain pre-configured ladder logic for typical industrial processes, allowing the system to automatically generate customized PLC logic by selecting and populating appropriate templates rather than creating logic from scratch, thereby reducing development time while maintaining customization capability
Solution Approach 2:
The system uses copying by creating copies of standardized PLC logic templates and populating them with specific process data. Instead of manually programming each logic statement, the system copies proven logic patterns and automatically fills them with device names, parameters, and configuration data from the specific application, significantly reducing programming time while preserving the ability to customize for different industrial processes
2Adaptability or versatility
If manual ladder logic programming is used, then complex industrial processes can be programmed, but the process becomes tedious and error-prone
Solution Approach 1:
The system achieves universality by creating a multi-functional platform that can handle various industrial processes through a single automated system. The template-based approach allows the same system to generate PLC logic for different applications (manufacturing, food processing, mining, pharmaceuticals) by selecting appropriate templates and populating them with process-specific data, making the system versatile while eliminating the tedium of manual programming
Solution Approach 2:
The system implements self-service by automatically generating PLC logic without requiring manual programming intervention. The system takes process configuration data as input, automatically selects appropriate logic templates, populates them with relevant parameters, and generates the final PLC logic statements, thereby eliminating the tedious manual programming process while maintaining the ability to handle complex industrial processes
Data Source
AI summary
A computer-implemented method according to an example embodiment of the present disclosure includes receiving programmable logic controller (PLC) configuration data for an industrial process. The PLC configuration data describes a PLC, a plurality of PLC assets, a plurality of PLC devices associated with the plurality of PLC assets, and network connectivity data for communication between the PLC and the PLC assets and PLC devices. The method also includes determining, from a repository of PLC ladder logic templates and based on the PLC configuration data, a set of PLC ladder logic templates that correspond to the plurality of PLC assets and PLC devices; and, based on the PLC configuration data and set of PLC ladder logic templates, creating PLC logic for performance of the industrial process. The PLC logic includes the set of PLC ladder logic templates populated with portions of the PLC configuration data. A system is also disclosed.