Runtime Server I/O Mapping for Online PLC Program Updates
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Solution Overview
Problem
In industrial automation, existing control programs for PLCs/NCs require interruption for changes, modifications, or updates, leading to downtime and disruption of automation system operations.
Innovation Solution
A runtime server that allows simultaneous execution of multiple runtime systems, enabling changes, modifications, or updates to individual application modules without stopping the entire system control program by using multiple runtime systems with data transmission interfaces, I/O configurations, and an intermediate I/O mapping layer for seamless data exchange and allocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If changes, modifications, or updates are made to the control program, then the control program can be improved or updated, but the automation system operation is interrupted causing downtime
Solution Approach 1:
The system divides the control program into multiple independent runtime systems (first runtime system, second runtime system). Each runtime system can be modified independently while the other continues to execute, allowing updates without complete system shutdown. The segmentation enables parallel execution of old and new versions.
Solution Approach 2:
The control program is prepared in advance with multiple runtime system versions loaded into memory. The system pre-configures the first and second runtime systems with different versions of the control program before switching between them, enabling seamless transitions without interruption.
2Device complexity
If a single runtime system is used, then the system structure is simple, but changes require stopping the entire system control program
Solution Approach 1:
The single runtime system is segmented into multiple parallel runtime systems (first runtime system, second runtime system). Each segment can be independently modified, loaded, and executed. This segmentation transforms the operational capability from requiring full system shutdown to allowing incremental online updates.
Solution Approach 2:
The system changes the operational parameter from single-instance execution to multi-instance parallel execution. By maintaining multiple runtime systems with different control program versions simultaneously, the system enables online modification while preserving operational continuity.
3Adaptability or versatility
If multiple runtime systems are executed simultaneously, then online changes are enabled, but the system complexity increases
Solution Approach 1:
Multiple runtime systems are merged into a single integrated execution environment managed by one controller. The controller coordinates the first and second runtime systems, handling their initialization, execution, and switching. This merging approach enables online updates while centralizing management complexity in a single control point.
Solution Approach 2:
The controller acts as an intermediary between the multiple runtime systems and the external environment. It manages the loading, execution, and switching of different runtime system versions, abstracting the complexity of multi-system management from the user and providing a unified interface.
Data Source
AI summary
A runtime server includes a plurality of simultaneously executing runtime systems, which are configured for real-time execution of a control program for an automation system. At least two of the runtime systems execute application modules of the control program, with at least one module executing an application of the control program being installed on each runtime system. Each runtime system has a data transmission interface for transmitting data between the runtime systems and/or application modules, an I/O configuration which defines an allocation between at least one variable of the application modules and at least one hardware address of a hardware component of the automation system, an I/O interface for data exchange between the runtime systems and hardware components, and an intermediate I/O mapping layer. The I/O configurations are mapped in the intermediate I/O mapping layer.