PLC Communication Module Configuration Validation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In programmable logic controller (PLC) systems, replacing a faulty communication module with a previously configured module for a different control system can result in incorrect configuration data being used, leading to system crashes during reboot, especially when traditional systems fail to distinguish between new and old modules or systems, causing invalid data to be used for component configuration.
Innovation Solution
A mechanism is implemented to determine the configuration scenario and select the appropriate configuration source, either internal memory or an external web-based source, by comparing redundancy checks and configuration times, ensuring valid configuration data is used during boot-up, and avoiding the use of invalid data from flash memory by using local copies of configuration data for component configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a previously configured communication module is reused in a different control system, then component reconfiguration is simplified, but incorrect configuration data may be used leading to system crashes
Solution Approach 1:
The system performs preliminary actions by checking configuration validity before applying settings. The processor compares redundancy checks and configuration times to determine whether configuration data is valid before applying it, preventing incorrect data from causing system crashes while still enabling module reuse.
Solution Approach 2:
The system implements feedback mechanisms where the communication module reports its configuration status, redundancy check results, and configuration time to the processor. This feedback loop enables the processor to make informed decisions about whether to apply configuration data from internal memory or fetch it from external sources, ensuring system reliability while maintaining ease of module replacement.
2Speed
If configuration data is stored in internal memory for quick access, then configuration speed is improved, but invalid data from flash memory may be used during boot-up
Solution Approach 1:
The processor performs preliminary validation checks by comparing redundancy checks and configuration times before applying configuration data from internal memory. This preliminary action ensures that only valid, recent configuration data is applied, preventing invalid data from causing system crashes while maintaining fast configuration loading.
Solution Approach 2:
The communication module provides feedback about its configuration state, including redundancy check results and configuration timestamps. This feedback enables the processor to validate configuration data before application, ensuring both speed and reliability by distinguishing between valid cached configuration and invalid flash memory data.
3Loss of time
If the system automatically uses stored configuration data during boot-up, then system startup time is reduced, but system crashes occur due to incorrect configuration
Solution Approach 1:
The processor performs preliminary validation of configuration data during boot-up by comparing redundancy checks and configuration times before applying any settings. This preliminary action allows the system to quickly boot up using stored configuration data while preventing crashes by ensuring the data's validity through comparison checks.
Solution Approach 2:
During boot-up, the communication module provides feedback about its configuration status and the processor uses this feedback to validate configuration data before application. This feedback mechanism enables fast startup by using stored configuration data while maintaining reliability through validation checks that prevent incorrect data from causing system crashes.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Aspects of the invention support a component configuration mechanism when rebooting a circuit module (201) of a programmable logic controller (101). A component (application) may be configured from a plurality of sources, including flash memory (204) and a web-based configuration source. The configuration mechanism avoids using invalid configuration data when replacing the communication module. The circuit module may support a plurality of components, where some of the components may be associated with a web-based configuration while other components may be associated with a CPU-based configuration. If the configuration data in the flash memory of the communication module is determined to be invalid, the communication module obtains configuration data from a web-based configuration source for a web-based configured component and from an associated CPU module (202) for a CPU-based configured component. The validity of configuration data in internal memory is determined by comparing values of cyclic checksums and configuration times.