PLC WebApp Engineering via Hypervisor-Separated Multicore Control
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Solution Overview
Problem
Current programmable logic controller (PLC) engineering systems require high-end computers with specific processing requirements and operating system compatibility, limiting their use to expensive hardware and restricting flexibility, especially for on-site configurations and lower-end devices.
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 device, enabling configuration and control through a web browser independent of the workstation's capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional engineering systems are used on workstation computers, then engineering tasks can be performed, but the workstation must meet high processing requirements and use expensive high-end computers
Solution Approach 1:
The patent segments the engineering system into two distinct parts: a lightweight web server that runs on the PLC and a web browser interface that runs on the workstation. This segmentation allows the workstation to be a low-cost device while the PLC handles the complex engineering system logic, resolving the contradiction between device cost and system functionality.
Solution Approach 2:
The patent introduces a web server as an intermediary component that runs on the PLC and provides engineering system functionality through standard web protocols. This intermediary allows any workstation with a web browser to access engineering capabilities without requiring the workstation itself to meet high processing requirements, thus resolving the cost-functionality contradiction.
2Ease of operation
If traditional engineering systems are used, then engineering tasks can be performed, but the system requires pre-installation and complex configuration management
Solution Approach 1:
The patent implements self-service by making the PLC itself host the engineering system web server. The PLC automatically provides engineering capabilities through its web interface without requiring external workstations to have pre-installed engineering software. This eliminates installation and configuration efforts on workstations, resolving the contradiction between ease of operation and time loss.
Solution Approach 2:
Instead of having the workstation run the engineering system software (traditional approach), the patent inverts the architecture by having the PLC run the engineering system web server. This inversion transfers the software burden from the workstation to the PLC, eliminating installation and configuration requirements on the workstation and resolving the setup effort-time contradiction.
3Adaptability or versatility
If traditional engineering systems are used, then engineering tasks can be performed, but software version compatibility between the engineering system and PLC must be maintained
Solution Approach 1:
The patent achieves universality by using standard web protocols (HTTP, HTML, JavaScript) as the communication interface between the PLC and workstation. Since web browsers are universally available on all modern devices, this approach provides broad workstation compatibility without requiring specific engineering software installations, resolving the adaptability-complexity contradiction.
Solution Approach 2:
The patent changes the communication parameter from proprietary engineering software protocols to standard web protocols. This parameter change enables any device with a web browser to access the PLC engineering interface, eliminating version compatibility issues between engineering software and PLC while reducing software version management complexity.
4Productivity
If traditional engineering systems are used, then engineering tasks can be performed, but administrative overhead increases in large organizations
Solution Approach 1:
The patent implements self-service by enabling field technicians to perform engineering tasks directly on-site using their own devices with web browsers. The PLC's embedded web server provides all necessary engineering functions without requiring centralized software deployment or configuration management, eliminating administrative overhead while maintaining engineering task efficiency.
Solution Approach 2:
The patent extracts the engineering system software from the workstation and relocates it to the PLC. This extraction eliminates the need for complex configuration management and software deployment across multiple workstations in large organizations, reducing administrative overhead while preserving engineering task efficiency through direct on-site access.
Data Source
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.