Virtual PLC Architecture for Parallel Multi-Application Control
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Solution Overview
Problem
Existing programmable logic controllers (PLCs) face increased system complexity and costs due to the need for separate controllers for different subsystems developed by different companies, necessitating high coordination efforts and incompatible software environments.
Innovation Solution
A programmable logic controller that simulates multiple virtual controllers, allowing independent execution of different application programs on a single hardware via a virtual field bus, enabling parallel operation without requiring identical software versions or libraries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate PLC controllers are used for different subsystems developed by different companies, then each subsystem can be developed independently, but system complexity and costs increase
Solution Approach 1:
The patent merges multiple separate PLC controllers into a single unified PLC system that can host multiple independent application programs. The single PLC includes a data processing unit that can execute multiple applications simultaneously, each developed by different companies using their own software environments and versions, while maintaining independent development capabilities. This consolidation reduces the number of physical controllers from multiple to one, thereby reducing system complexity and costs while preserving the ability of different subsystems to be developed independently.
Solution Approach 2:
The single PLC controller is designed with universal functionality to support multiple different application programs from different development environments. The data processing unit can load and execute multiple applications with different software versions and libraries, making the single controller capable of performing the functions that previously required multiple specialized controllers. This multi-functionality allows different subsystems to operate independently on the same hardware platform.
2Ease of manufacture
If separate PLC controllers are used for different subsystems, then coordination efforts between companies are reduced, but hardware costs and system complexity increase
Solution Approach 1:
The patent combines multiple separate PLC controllers into a single unified system. Instead of having each company deploy their own separate controller, multiple application programs from different companies are consolidated onto one PLC. This reduces the quantity of controllers from multiple to one, directly addressing the worsening feature while the independent execution of applications maintains the ease of manufacture benefit by allowing each company to develop their application independently using their preferred tools and environments.
3Device complexity
If multiple application programs run on a single PLC, then system complexity and costs are reduced, but coordination efforts between different software environments increase
Solution Approach 1:
The patent segments the software architecture within the single PLC to handle multiple different software environments. Each application program runs in a separate, isolated environment within the data processing unit, allowing different software versions and libraries to coexist without interference. This segmentation enables the PLC to manage multiple applications from different development companies, each with their own software requirements, while maintaining overall system simplicity through a single unified hardware platform.
Data Source
AI summary
A programmable logic controller, a method for operating a programmable logic controller, and a computer program product provide for parallel operation of a plurality of PLC applications on a programmable logic controller. The programmable logic controller has a data processing unit, at least one input, at least one output, and at least one storage region for application programs, wherein the programmable logic controller is configured to provide at least one virtual programmable logic controller during operation by means of an operating system, wherein an application program is able to be run on the virtual programmable logic controller.