Shared Process Images Across PLCs Without Logic Remapping
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Solution Overview
Problem
Existing industrial automation systems face challenges in efficiently managing and sharing Input/Output (IO) process images across multiple programmable automation controllers in distributed automation systems, requiring modifications to logic when function blocks need to be distributed to different controllers.
Innovation Solution
A method and system for sharing process data between controllers, utilizing a first and second runtime environment with process data managers linked via communication lines, allowing any part of the application to access the IO process image independently of its mapping, with deterministic data paths and high reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If process images are isolated on each controller, then controller reliability is maintained, but data sharing efficiency deteriorates
Solution Approach 1:
The system divides the process image into separate process image parts, each assigned to specific controllers. Each controller maintains its own process image part independently, ensuring local reliability while enabling selective sharing of specific parts across controllers through the communication network.
Solution Approach 2:
A communication network acts as an intermediary between controllers, enabling process image part data to be shared selectively. The communication network facilitates data exchange without requiring direct coupling between controllers, maintaining independence while enabling collaboration.
2Adaptability or versatility
If function blocks are distributed to different controllers, then system versatility is improved, but logic complexity increases
Solution Approach 1:
The automation application is segmented into function blocks that can be independently distributed to different controllers. Each function block operates with its associated process image part, simplifying the distribution logic while maintaining system versatility.
Solution Approach 2:
The system creates a universal architecture where function blocks can be freely distributed across multiple controllers without requiring controller-specific logic modifications. The standardized process image sharing mechanism enables the same function block to operate uniformly on any controller.
3Stability of the object's composition
If process image is bound to specific controller, then controller stability is maintained, but adaptability deteriorates
Solution Approach 1:
The process image is segmented into multiple process image parts that can be independently assigned to different controllers. This segmentation allows the application to adapt to different controller configurations while each controller maintains stable operation with its assigned process image part.
Solution Approach 2:
The system transitions from a single-dimension controller-bound process image to a multi-dimensional architecture where process image parts can be independently distributed across multiple controllers. This dimensional change enables flexible reconfiguration without compromising individual controller stability.
Data Source
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AI summary
For sharing process data from a first controller (CT1) to a least a second controller (CT2), the first controller (CT1) and the second controller (CT2) including respectively a first runtime environment (RE1) and a second runtime environment (RE2) to execute at least a distributed automation application (Daa) and including respectively a first process data manager (PDM1) and a second process data manager (PDM2) to manage respectively a first process image (PI1) and a second process image (PI2), the first process data manager and the second process data manager being linked respectively to a first set of communication devices (CD1) and to a second set of communication devices (CD2) via a first communication line (CL1) and being linked between them via a second communication line (CL2), a system comprises: the first controller (CT1) retrieving (S2) process data from the distributed automation application (Daa) or from a communication device of the first set of communication devices (CD1), the first controller (CT1) updating (S3) the first process image (PI1) with the retrieved process data, the first controller (CT1) sending (S4) the process data on the second communication line (CL2), the second controller (CT2) receiving (S5) the process data sent on the second communication line (CL2) and updating the second process image (PI2) with the received process data.