Rockwell Automation Technologies Incorporated

Allen-bradley Company, LLC

Michael J Viste

Charles Martin Rischar

Joseph P Izzo

Filip Macurek

Petr Pitrinec

Ladislav Bumbalek

David Allen Johnston

Christopher Wayne Como

Jatin P Bhatt

Jeffery William Brooks

William G Onarheim

David J Morley

Barbara E Meyer

Horace Dudley

Ryan L Schnell

Joseph Paul Izzo

An industrial controller that integrates execution of a control program on the industrial controller with execution of additional functions on an external processing device is disclosed. Integrating the external processing device provides an improved system for third party development of control functions which may be unique to specific applications. The system manages communication between the industrial controller and the external processing device, manages access to data stored in the industrial controller, and makes the details of the integration transparent to the programmer.

Method and apparatus for proxy execution and computation with an industrial controller

Different cores of a multicore processor are used to provide diagnostics of sophisticated hardware without full redundancy by static assignment of the cores during individual cycles of the control program and comparison of the outputs. A method of automatically generating diverse programs for execution by these cores may modify one program to compile two different instructions without functionally changing that program through the use of DeMorgan equivalents and diverse compiler optimizations.

Safety industrial controller providing diversity in single multicore processor

Various embodiments of the present technology generally relate to methods and systems for providing a flexible, updatable, and backward compatible programmable logic controller ('PLC') and instruction set library. The instruction set library in the PLC can be updated without downtime of the PLC or the machines controlled by the PLC. The instruction set library is decoupled from the PLC firmware and bound via an API so that instructions in the executable code are bound to the firmware such that updates to the instruction set library can happen between scans of the executable without requiring the firmware be updated. Further, the instruction set library may be partitioned to limit updates and the amount of the complete instruction set library that is stored on the PLC to only those used by the PLC.

Supporting instruction set architecture components across releases

Embodiments of this present disclosure may include industrial components in an industrial environment and a control system. The control system may receive a request to perform a control operation using the industrial components and may access a reference array associated with the industrial components. The reference array may include rows and columns, where each row may correspond to a respective industrial component of the industrial components. The control system may identify or program set points in the reference array associated with completing the control operation and may detect current motion components of the plurality of industrial components. The control system may generate control commands for the industrial components based on the current motion components, the set points, and/or the reference array. The industrial components may perform the control operation in response to receiving the control commands.

Automation control based on a reference array

Systems are provided for a 'loadable module' architecture for industrial controllers in which new control program modules which provide updated functions or features may be loaded to extend or modify the underlying operating system and/or other services without updating the firmware and without disrupting or otherwise compromising the ability of the industrial controller to maintain continuous control over the controlled process. Control program modules and libraries may be delivered to the industrial controller in object code format and an embedded linker in the industrial controller may be used to efficiently create fully linked and executable files locally. Loadable libraries may be provided to the industrial controller during runtime to extend functionality and/or provide desired fixes. As a result, a system is provided that is more efficient and that enables significant flexibility in adding new capabilities.

Techniques for improving industrial control systems

The present inventors have recognized that highly reliable operation may be further achieved in industrial control systems by monitoring execution of programs in real time. Such monitoring may include detecting defective program sequences which may be caused by executing a wrong sequence, executing a sequence at a wrong time, and/or a faulty clock. In one aspect, a control program may be divided into executable modules. A first code stream may then execute to control an industrial process or machine using the executable modules stored in a first set. In addition, a second code stream may execute to verify the first code stream using executable modules stored in a second set. First and second execution sequence values may be generated based on execution of the first and second code streams. A comparison of the first and second execution sequence values may detect an error which may have occurred in the program.

Industrial control program sequence monitoring

The inventor has recognized that industrial controllers may be updated after they are deployed in the field, while actively controlling an industrial process and without costly downtime, by storing a replacement machine-readable component in an allocated program space, locating and modifying one or more dependent machine-readable components copied in the allocated program space to instead depend on the replacement machine-readable component, re-linking a copy of the control program in the allocated program space, and redirecting execution to the control program in the allocated program space. Replacement machine-readable components could be instructions, libraries, or subroutines of the control program, and are not limited to user logic. The control program in the allocated program space may optimally be tested by verifying an operation before redirecting execution to the control program in the allocated program space.

System for updating a control program actively controlling an industrial process

Graphical editing methods are employed to construct programs in high-level graphical languages prior to compilation and operation in controllers for industrial or commercial equipment. The editing methods include process, hardware and program editing tasks for defining both process and hardware I/O points and connecting them to variables in a controller program. Each editing task has a tree graph window, a graph editing window, and a palette with rotating panels of graphical editing tools. The hardware editing taks uses two-layered icons to graphically simulate the hardware environment. A plurality of graph types are based on generalized node-vert-arc graphical elements which are special classes programmed in the Smalltalk programming language. Languages for the controller program include function block, sequential function chart and ladder diagram.

Growing community of inventors

Grafton, WI, United States of America

Michael J Viste