PLC Web Engineering Server Using Hypervisor-Based Core Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current programmable logic controller (PLC) engineering systems require high-end computers, are not portable, and demand significant administrative effort due to compatibility and software version synchronization issues, limiting their use in cost-effective and efficient configuration and programming, especially in field settings.
Innovation Solution
A device-based engineering system utilizing a multicore processor with a hypervisor to run separate operating systems on each core, allowing a web-based engineering server and application to be executed on a lower-end device, enabling configuration and control of PLCs through a web browser, independent of the device's processing requirements and OS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional engineering systems are used on workstation computers, then PLC configuration and programming functionality is provided, but high-end expensive computers are required due to minimum processing requirements
Solution Approach 1:
The system segments the engineering functionality into a web server component that runs on the PLC and a web browser component that runs on the workstation. This separation allows the heavy processing requirements to be handled by the PLC's embedded web server while the workstation only needs to run a standard web browser, enabling use of lower-cost devices.
Solution Approach 2:
A web server acts as an intermediary between the PLC and the workstation computer. The web server runs on the PLC and provides engineering functionality through standard web protocols, allowing any workstation with a web browser to access PLC configuration and programming without requiring specialized software or high-end hardware.
2Adaptability or versatility
If traditional engineering systems are installed on workstation computers, then PLC engineering tasks can be performed, but the system is not portable and is restricted to specific operating systems
Solution Approach 1:
The engineering system is made universal by implementing it as a web server on the PLC that can be accessed by any workstation with a standard web browser. This eliminates OS-specific restrictions and portability issues, as web browsers are universally available across different platforms and devices including laptops, tablets, and desktop computers.
Solution Approach 2:
Instead of installing engineering software on the workstation, the invention inverts the approach by placing the engineering server on the PLC itself. The PLC becomes the service provider and the workstation becomes the client, eliminating the need for complex software installation and configuration on the portable device.
3Productivity
If traditional engineering systems are pre-installed on workstation computers, then PLC configuration functionality is available, but significant time and effort is required for installation, configuration, and software updates
Solution Approach 1:
The PLC performs self-service by running its own embedded web server that provides engineering functionality. This eliminates the need for external workstations to have specialized software installed, as the PLC serves the engineering functions directly. Updates and maintenance are handled on the PLC side without affecting the workstation.
Solution Approach 2:
The engineering functionality is pre-configured and built into the PLC's firmware, eliminating the need for installation and configuration steps on the workstation. The web server is already running on the PLC when it is powered on, allowing immediate access to configuration functions.
4Ease of operation
If traditional engineering systems are used, then PLC configuration and programming is possible, but version compatibility between ES and PLC software must be maintained requiring substantial time and effort
Solution Approach 1:
The engineering system and PLC software are merged into a single integrated platform. The web server runs on the PLC itself, ensuring inherent version compatibility since both the service and the controlled device are part of the same system. This eliminates the need to manage separate software versions and their compatibility relationships.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system for configuration and control of a device includes a device processor includes at least two processing cores. Device firmware executes on a first processing core and a device-based engineering server executes on a second processing core. A web server running on the device-based engineering server includes a webApp providing web-based functionality for configuration and control of the device. The webApp is downloaded from the web server to the user's browser. A hypervisor manages communication between the device firmware and the device-based engineering server. A communication path established in the hypervisor for communicating a configuration or control instruction to the device firmware. The configuration or control instruction is initiated by a user via a web browser. The users web browser may run on a computer workstation that does not otherwise meet processing requirements of an engineering system for the device.