Virtual PLC Input Modules for External AI Service Integration

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Solution Overview

Problem

Current PLC technologies cannot seamlessly integrate external analytic tools or algorithms for online optimization, relying on empirical data and parameterization of functional modules.

Innovation Solution

The creation of virtual functional modules within PLCs, allowing for the mapping of external service provider data (like industrial cloud platforms or AI algorithms) to PLC input channels, enabling online integration and adaptive process control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If parameterization of functional modules is used for process control optimization, then empirical data can be utilized, but external analytic tools or algorithms cannot be integrated online

Engineering Contradiction:

Improveintegration capability with external analytic toolsVSAvoidPLC system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces a virtual functional module as an intermediary component that bridges the PLC and external analytic tools. This virtual module acts as a mediator that enables data exchange and integration between the PLC's control system and external analytical services without requiring direct complex connections, thus solving the contradiction between integration capability and system complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The virtual functional module is designed with universal functionality that can interface with multiple types of external analytic tools and algorithms. It provides a standardized interface that can handle various data formats and communication protocols, enabling the PLC to integrate diverse external services through a single unified mechanism

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If traditional PLC configuration methods are used, then the system structure remains simple, but external data sources cannot be used as normal input values

Engineering Contradiction:

Improvedata source integration capabilityVSAvoidconfiguration ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent creates a virtual copy of a functional module that mimics the behavior and interface of traditional PLC input modules. This virtual functional module copies the standard input channel interface, allowing external data sources to be used exactly like normal PLC inputs without requiring changes to existing PLC programs or configuration methods, thus maintaining ease of operation while enabling enhanced adaptability

Inventive Principle:

Principle #26Copying

Data Source

PatentUS11640152B2Method and device for providing service for a programmable logic controller

Publication Date: 2023.05.02 SIEMENS AG

AI summary

Embodiments of the present disclosure provide method and device for providing service for a programmable logic controller (PLC), including: creating a virtual-functional-module-description file including an address of an input channel of a virtual functional module to be created; and creating the virtual functional module in a PLC based on the virtual-functional-module-description file, assigning the address to the input channel of the virtual functional module, and creating a virtual-functional-module-configuration file including a mapping relation between the input channel and an output of a service provider. The present disclosure proposes a concept of a virtual functional module which is used to map data provided by intelligent data sources outside the PLC to input channel of PLC so that the data can be the same as normal input values used by PLC program.