PLC Configuration for Automated Sensor-Actuator Subsystems
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Solution Overview
Problem
The selection of a Programmable Logic Controller (PLC) for industrial plant sub-systems is typically done early in the planning phase and involves manual upload of control programs, lacking support for automation in the selection process.
Innovation Solution
A computer-implemented method for configuring industrial plant sub-systems using a Global Discovery Service (GDS) database to store descriptions of sensors, actuators, and PLCs, allowing for the selection of a suitable PLC based on a controller program, generating an application for the selected PLC, and transferring it to configure and connect sensors and actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PLC selection is done manually in the planning phase, then flexibility in selection is maintained, but time consumption and complexity increase
Solution Approach 1:
The system changes parameters by storing multiple PLC descriptions with varying capabilities in a database and automatically selecting based on matching controller program requirements, transforming manual selection into an automated parameter-matching process that reduces time while maintaining flexibility
Solution Approach 2:
The system enables self-service by allowing the controller program and database to automatically determine suitable PLCs without manual intervention, with the selection process serving itself through automated compatibility checking and recommendation generation
2Ease of manufacture
If manual upload of control programs is used, then simplicity in process is maintained, but productivity and automation level decrease
Solution Approach 1:
The system replaces manual mechanical processes (physical PLC configuration and program uploading) with automated electronic processes, where software automatically generates configuration data and transfers programs, increasing productivity while maintaining ease of use through graphical interfaces
Solution Approach 2:
The system achieves universality by creating a multi-functional automated configuration platform that handles PLC selection, program generation, configuration data creation, and program transfer in a single integrated process, improving productivity without sacrificing simplicity
3Stability of the object's composition
If specific PLC types are selected early in planning, then system stability is improved, but adaptability to different PLCs decreases
Solution Approach 1:
The system applies segmentation by separating the controller program from specific PLC hardware, allowing the program to be developed independently and then adapted to different PLC types through automated configuration, maintaining stability while enabling adaptability
Solution Approach 2:
The system introduces dynamics by making the PLC configuration adaptable and changeable after initial selection, allowing automatic reconfiguration when switching PLC types, thus maintaining system stability while enabling flexibility for different PLC implementations
Data Source
AI summary
A system and method includes storing a description of at least one sensor in a database; storing a description of the at least one actuator in the database; storing a PLC-list comprising a description of the at least one PLC in the database; writing a controller program that describes an action of the at least one actuator caused by the at least one sensor; selecting, based on the database and the controller program, a PLC of the PLC-list, which is able to functionally connect the sensor and the actuator; generating an application for controlling the selected PLC based on the selected PLC and the controller program; and transferring the application to the selected PLC thus configuring and/or functionally connecting the at least one sensor and the at least one actuator of the sub-system.