Virtual Hardware Interface for PLC Software Migration

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Solution Overview

Problem

Existing programmable logic controllers (PLCs) require significant manual adaptation and testing of control software when hardware or communication systems are changed, leading to high costs and difficulties in modernizing industrial control systems, especially in safety-relevant applications.

Innovation Solution

A platform with an execution environment and external interface that uses virtual hardware and a switching unit to bidirectionally translate data, decoupling control logic from hardware and network connections, allowing control software to function unchanged across different hardware and network configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If control software is manually adapted when hardware or communication systems are changed, then software functionality can be maintained, but adaptation costs and time increase significantly

Engineering Contradiction:

Improvesoftware functionalityVSAvoidadaptation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent introduces a virtual hardware layer as an intermediary between the control software and physical hardware. This virtual layer acts as a mediator that translates between the software's hardware-specific operations and the actual physical hardware operations, allowing software to run unchanged on different hardware platforms while maintaining full functionality through automated translation rather than manual adaptation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If control software is manually adapted when hardware or communication systems are changed, then software functionality can be maintained, but adaptation costs increase

Engineering Contradiction:

Improvesoftware functionalityVSAvoidadaptation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The virtual hardware layer serves as a cost-effective intermediary that automatically handles hardware abstraction. Instead of requiring expensive manual software adaptation for each hardware change, the system uses the virtual hardware translation layer that can be configured once and reused across multiple hardware platforms, significantly reducing adaptation costs while maintaining software functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The virtual hardware layer provides universal compatibility across different hardware platforms. A single control software implementation can operate on multiple different physical hardware configurations through the virtual hardware abstraction, eliminating the need for separate software versions for each hardware type and reducing overall adaptation costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If control software is manually tested after hardware changes in safety-relevant applications, then safety can be ensured, but testing effort and costs increase

Engineering Contradiction:

ImprovesafetyVSAvoidtesting effort

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The virtual hardware layer acts as a safety-preserving intermediary that isolates the control software from hardware-specific variations. Since the virtual layer handles all hardware translation consistently, the same software can be tested once on reference hardware and then safely deployed to different hardware platforms without requiring extensive re-testing, thereby maintaining safety while reducing testing effort.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If control software is decoupled from hardware using virtual hardware and switching units, then adaptability to different hardware configurations improves, but system complexity increases

Engineering Contradiction:

Improvehardware compatibilityVSAvoidsystem structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system is segmented into distinct functional layers: control software, virtual hardware layer, and physical hardware layer. This segmentation allows each layer to be developed, tested, and modified independently. The virtual hardware layer is further segmented into configurable translation rules that can be adjusted for different hardware targets without affecting the core control software, improving adaptability while managing complexity through structured division.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10890887B2Platform for continued use of existing software for the actuation of industrial field devices

Publication Date: 2021.01.12 ABB (SCHWEIZ) AG

AI summary

A platform for actuation of at least one industrial field device in an industrial installation having control software includes: an execution environment, in which the control software is runnable; and an external interface for communicating between the control software and the at least one industrial field device. The execution environment has virtual hardware which, from a point of view of the control software, behaves in a manner of the at least one industrial field device. A switching unit is connected between the virtual hardware and the external interface. The switching unit bidirectionally translates data, interchanged between the control software and the virtual hardware, for communication with the at least one industrial field device via the external interface.