Universal PLC Interface for Industrial Energy Equipment
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Solution Overview
Problem
Current digital energy networks face challenges in efficiently monitoring and controlling diverse industrial energy devices due to the lack of a universal interface, requiring tedious and costly configuration of programmable logic controllers (PLCs) with custom firmware and extensive register mapping for various devices and manufacturers, leading to complex and unmanageable firmware code.
Innovation Solution
A system with dynamically configurable interface devices that receive configuration data from a server, including port and device definitions, allowing for easy adaptation to changing equipment setups, eliminating the need for register-specific requests and enabling efficient data retrieval and control through variable name/value pairs, reducing the complexity of managing multiple device types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If custom firmware is loaded on each PLC with specific I/O register maps for different devices, then the system can accurately monitor and control specific industrial energy devices, but the configuration becomes tedious, expensive, and time-consuming
Solution Approach 1:
The patent implements a universal PLC firmware that can interface with multiple types of industrial energy devices without requiring custom configuration for each device type. The system uses a standardized data model and common interface that automatically adapts to different devices (generators, chillers, pumps, etc.), eliminating the need for device-specific firmware compilation and I/O register mapping.
Solution Approach 2:
The system performs automatic device discovery and configuration before operation begins. The PLC automatically detects connected devices, retrieves their capabilities through standardized queries, and configures the data model accordingly without requiring manual intervention. This preliminary automatic configuration eliminates the time-consuming manual I/O register mapping process.
2Adaptability or versatility
If registers are reserved on each PLC for every potential device type and manufacturer, then the system can accommodate any device combination, but the firmware code becomes enormous and unmanageable
Solution Approach 1:
The patent implements a dynamic configuration system where the PLC firmware structure adapts automatically based on the actual devices connected to the system. Rather than having static reserved registers for all potential devices, the system dynamically creates the appropriate data model and register mappings only for the devices that are actually present, keeping the firmware lean and manageable.
Solution Approach 2:
The system segments the device interface into standardized functional components rather than monolithic device-specific interfaces. Each device type is broken down into common functional elements (status registers, control registers, parameter storage) that can be independently configured, allowing the firmware to handle device diversity through modular, manageable segments rather than overwhelming monolithic code.
3Reliability
If the I/O register map and firmware are changed whenever devices connected to the PLC change, then the system maintains accuracy, but the configuration process becomes even more tedious and expensive
Solution Approach 1:
The PLC system performs self-configuration by automatically detecting device presence, retrieving device capability information through standardized protocols, and generating the appropriate I/O register maps without external intervention. This self-service capability maintains data accuracy while eliminating the need for manual reconfiguration when devices are added or removed from the system.
Solution Approach 2:
The system implements continuous feedback mechanisms where the PLC automatically queries connected devices to verify their status and capabilities, and adjusts the configuration accordingly. This feedback loop ensures data accuracy is maintained while the system adapts to device changes automatically, removing the burden of manual reconfiguration from the user.
4Device complexity
If not enough registers are available on the PLC to account for all various device combinations, then the system remains simple, but it cannot support diverse device configurations
Solution Approach 1:
The patent introduces a virtual dimension through software-based data modeling that extends the physical register space of the PLC. By implementing a layered architecture with standardized data models and virtual memory mapping, the system can support an unlimited number of device types and configurations without being constrained by the physical register count, maintaining PLC simplicity while dramatically increasing adaptability.
Data Source
AI summary
A digital energy system monitors and controls a plurality of industrial energy devices. The system includes a server and one or more interface devices coupled to the industrial energy devices. Each of the interface devices has a dynamically configurable runtime environment. The server sends configuration data to each of interface devices. The configuration data includes variable definitions that reference specific registers on the industrial energy devices. The server monitors the industrial energy devices by obtaining values for one or more of the variables set forth in the variable definitions. To control an industrial energy device, the server sends a write request for the industrial energy device to the interface device with a value for a defined variable in the device definition for the industrial energy device.