PLC Programming Adaptation via Process Data Image Syntax
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Solution Overview
Problem
Manual adjustment of central controllers to process data images from subordinate controllers in industrial automation is time-consuming, error-prone, and costly, requiring frequent updates due to changing programming and data structures.
Innovation Solution
A method that uses a machine-readable syntax for process data images to automatically or partially automatically adapt the programming of central controllers, eliminating the need for manual input of structure information, allowing for flexible and efficient processing of data from various sensors and actuators through fieldbus networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment of central controllers is used to adapt to process data images from subordinate controllers, then the central controller can process the data correctly, but the process is time-consuming, error-prone, and costly
Solution Approach 1:
The subordinate controller automatically generates device description information containing process data image syntax and transmits it to the central controller. This self-service mechanism eliminates the need for manual configuration at the central controller, allowing the system to adapt automatically to programming changes at the subordinate controller while maintaining data processing correctness.
Solution Approach 2:
A device description information structure acts as an intermediary between the subordinate controller and central controller. This intermediary carries syntax information about the process data image, enabling the central controller to interpret data correctly without manual configuration, thus resolving the contradiction between reliability and time loss.
2Adaptability or versatility
If manual adjustment of central controllers is used to adapt to process data images, then data processing can be configured, but the process is expensive and error-prone
Solution Approach 1:
The subordinate controller automatically generates and transmits device description information that reflects its current programming and process data image syntax. This self-service approach enables flexible programming changes at the subordinate controller to be automatically communicated to the central controller, maintaining adaptability while eliminating manual configuration complexity and errors.
Solution Approach 2:
The device description information containing syntax definitions is generated and transmitted in advance before actual data exchange occurs. This preliminary action allows the central controller to be pre-configured with the correct interpretation rules, enabling flexible programming changes without subsequent manual adjustment and reducing implementation complexity.
3Adaptability or versatility
If frequent programming changes are made to subordinate controllers, then system functionality can be updated, but manual re-adjustment of central controllers is required each time
Solution Approach 1:
The subordinate controller automatically generates updated device description information whenever its programming changes and transmits this information to the central controller. This self-service mechanism enables frequent programming updates at the subordinate controller to be automatically reflected at the central controller, maintaining adaptability while eliminating repetitive manual re-adjustment work and improving configuration efficiency.
Solution Approach 2:
The device description information acts as feedback from the subordinate controller to the central controller, automatically conveying syntax changes resulting from programming updates. This feedback mechanism ensures the central controller remains synchronized with subordinate controller changes, enabling frequent updates without reducing productivity through manual re-adjustment.
Data Source
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AI summary
The invention relates to a method comprising the steps of: - coupling a central controller, in particular a first programmable logic controller (PLC), with a subordinate controller, in particular a second PLC, by means of a fieldbus connection, - programming the subordinate controller, wherein the programming causes the subordinate controller to output a process data image dependent on the programming, - generating a device description of the subordinate controller, wherein the device description includes a syntax of the process data image, - using the syntax to process the process data image by means of the central controller.