PLC Update Scheduling by Impact Level and Downtime Window
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Solution Overview
Problem
Existing firmware update scheduling methods for IoT devices in manufacturing factories do not adequately account for the impact level of updates, leading to potential system availability issues if the update causes operational disruptions.
Innovation Solution
A method for determining the impact level of software or firmware updates on programmable logic controllers (PLCs) and scheduling updates during non-operational time slots based on this impact level, with higher impact updates requiring longer downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If firmware update is executed over-the-air based on IoT device activity information, then the firmware update can be performed remotely, but the system availability may decrease if the update causes operational disruptions
Solution Approach 1:
The system performs preliminary actions by determining the impact level of the firmware update before execution. It schedules the update during pre-identified non-operational time slots, ensuring that updates are performed in advance during appropriate periods rather than during critical operational phases.
Solution Approach 2:
The system dynamically adjusts the update scheduling based on the determined impact level. Different impact levels correspond to different non-operational time slot requirements, allowing the system to adapt the update execution timing and duration according to the specific update's potential impact on system availability.
2Productivity
If firmware update is performed during operational time, then system productivity is maintained, but the risk of disabling booting and reducing availability increases
Solution Approach 1:
The system performs preliminary assessment by determining the impact level of the firmware update before execution. It schedules the update during pre-identified non-operational time slots, ensuring that updates are performed in advance during appropriate periods rather than during critical operational phases.
Solution Approach 2:
The system changes the timing parameter of update execution based on the impact level assessment. By transitioning from operational time slots to non-operational time slots for high-impact updates, the system adjusts when updates occur to balance productivity maintenance with availability protection.
3Reliability
If impact level determination and non-operational time slot selection is implemented, then system availability is maintained, but the update scheduling complexity increases
Solution Approach 1:
The update scheduling system is segmented into distinct functional components: impact level determination module, non-operational time slot selection module, and update execution module. This segmentation allows each component to handle specific tasks independently, making the overall complex system more manageable and maintainable.
Solution Approach 2:
The impact level determination acts as an intermediary between the firmware update request and the scheduling execution. It mediates the decision-making process by assessing the update's potential impact and translating this assessment into appropriate scheduling decisions, thereby managing complexity through a structured intermediate evaluation layer.
Data Source
AI summary
Example implementations described herein involve systems and methods for managing a plurality of programmable logic controllers (PLC), which can involve, for a detection of an update to one or more of a software or a firmware installed on a PLC of the plurality of PLCs being available, determining an impact level of the update to the one or more of the software or the firmware installed on the PLC of the plurality of PLCs; selecting a non-operational time slot for the PLC of the plurality of PLCs based on the impact level, wherein higher impact levels are indicative of requiring a longer non-operational time slot; and scheduling the update to the one or more of the software or the firmware installed on the PLC of the plurality of PLCs during the non-operational time slot.