PLC Symbol Structure for Automated Input Output Model Generation
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Solution Overview
Problem
The existing methods for testing programmable logic controller (PLC) codes are inefficient and prone to human error, requiring extensive knowledge and time to construct accurate plant models, making it difficult to distinguish between errors in the PLC code and the plant model during testing.
Innovation Solution
A programmable logic controller (PLC) symbol structure that automatically generates an input/output model using a simulation apparatus, which includes a PLC code storing unit, a model defining unit, a symbol extracting unit, a state defining unit, and a state control unit, to simulate PLC code testing by organizing PLC symbols into levels identified by an under-bar '_' and controlling state transitions based on input/output identifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plant model is constructed manually by analyzing PLC code, then the model can be used for testing, but the process requires substantial time and effort and cannot assure complete accuracy
Solution Approach 1:
The patent creates a virtual copy of the PLC code structure by generating a plant model automatically from the PLC code using a computer-readable recording medium. This copying process eliminates manual construction while preserving the functional relationships, thereby reducing time investment while maintaining accuracy.
Solution Approach 2:
The patent replaces the manual mechanical process of analyzing and constructing plant models with an automated computational system. The computer-readable recording medium enables automatic generation of the plant model from PLC code, substituting human cognitive effort with algorithmic processing.
2Reliability
If manual analysis is used to construct a plant model, then the model reflects the PLC code functionality, but it is difficult to identify whether errors are in the PLC code or the plant model
Solution Approach 1:
The patent implements a feedback mechanism where the plant model is automatically generated from the PLC code and can be used to test and verify the original code. This creates a closed-loop system where errors can be traced back to their source through systematic comparison between the PLC code and its generated model.
Solution Approach 2:
By creating an exact structural copy of the PLC code in the form of a plant model through automatic generation, the patent enables direct comparison and error tracing. The copied structure maintains fidelity to the original, allowing systematic verification and error identification.
3Ease of manufacture
If extensive knowledge is required to write PLC code, then the code can be implemented, but the same level of knowledge is required to test it, increasing complexity
Solution Approach 1:
The patent creates a simplified virtual representation (plant model) that copies the essential functionality of the PLC code without requiring the same level of specialized knowledge for construction or testing. This copying approach enables testing with reduced expertise requirements.
Solution Approach 2:
The plant model serves as an intermediary between the PLC code and the testing process. Instead of directly testing the complex PLC code, the automated system uses the generated plant model as a mediator, simplifying the testing procedure and reducing the knowledge barrier.
Data Source
AI summary
Disclosed are a PLC (Programmable Logic Controller) symbol structure for a PLC code for automatically generating an input/output model, and a simulation apparatus and a simulation method for testing the PLC code using the same. In one embodiment, a computer-readable recording medium records a PLC code including a plurality of PLC symbols, wherein each of the PLC symbols includes a plurality of levels identified by an identifier, and a computer automatically generates an input/output model using the structure of each of the PLC symbols, thereby performing a simulation for testing the PLC code. The PLC symbol structure according to one embodiment systematically contains information required for automatically generating the input/output model, making it possible to automatically generate the input/output model for testing the PLC code in an easier manner without knowledge of simulation and modeling, and reducing the time consumed and the labor required for generating the input/output model.