Wireless PLC Access Point for Secure Cabinet-Free Maintenance
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Solution Overview
Problem
Industrial automation devices require remote access for maintenance while maintaining power availability and security, as existing methods like lock-out, tag-out procedures are cumbersome and pose security risks when allowing third-party access to programmable logic controllers.
Innovation Solution
A portable memory device with a programmable logic controller (PLC) provides a local wireless access point via an antenna, enabling remote connection without opening control cabinets, using protocols like Wi-Fi, Bluetooth, 3G, 4G, 5G, or Lora, and employing public key/private key encryption for security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lock-out, tag-out procedures are performed to access control cabinets, then safety is improved, but access complexity and downtime increase
Solution Approach 1:
A wireless access point device is introduced as an intermediary between the PLC and maintenance personnel. This device provides remote access capabilities through wireless communication, eliminating the need for physical access to control cabinets and the associated lock-out, tag-out procedures. The intermediary device handles authentication and data transmission, allowing safe remote maintenance while keeping the main system operational.
2Ease of operation
If physical access to control cabinets is required, then direct PLC access is improved, but security risks increase
Solution Approach 1:
The wireless access point serves as a secure intermediary that mediates all communications between maintenance personnel and the PLC. It implements authentication protocols and encrypted data transmission, allowing direct PLC access functionality while eliminating security risks associated with physical cabinet access. The intermediary device filters and secures all data exchanges.
Solution Approach 2:
The patent replaces the mechanical approach of physically opening control cabinets and directly connecting to PLCs with a wireless communication system. This substitution eliminates the need for physical access while maintaining full operational access to the PLC through wireless data transmission and remote interface capabilities.
3Reliability
If power is removed for maintenance access, then safety is improved, but productivity decreases
Solution Approach 1:
The wireless access point enables maintenance operations to be performed remotely without requiring power shutdowns. By providing secure remote access to PLC data and control functions, the intermediary device allows maintenance personnel to diagnose and repair issues while the industrial automation system remains fully operational, eliminating productivity loss.
Solution Approach 2:
The system performs preliminary authentication and connection establishment through the wireless access point before any maintenance operations begin. This preliminary setup enables safe remote access without requiring subsequent power interruptions, allowing continuous operation throughout the maintenance process.
Data Source
AI summary
A non-transitory, computer-readable medium, comprising instructions that when executed by one or more processors, cause the one or more processors to perform operations that include receiving a request to connect to the wireless access point from a computing device. The request includes a private key. The operations may also include comparing the private key to an index of public keys associated with respective users authorized to connect to the wireless access point, determining that the computing device is authorized to connect to the wireless access point based on the comparison, authorizing the computing device to connect to the wireless access point, encrypting maintenance data associated with one or more industrial automation devices, and transmitting the encrypted maintenance data to the computing device via the wireless access point.