Automated configuration of an industrial controller by means of a verification token

Abstract

A method for an automated configuration of an industrial controller unit comprises sending, from a server system, an instruction message and a verification token to a client device via a first communication network. The instruction message comprises information pertaining to a modification of an industrial controller unit, and the verification token pertains to a completed modification of the industrial controller unit. The method further comprises receiving, at the server system, a verification message pertaining to the verification token, and providing, from the server system, an industrial program and/or a parameter for an industrial program to the industrial controller unit via a second communication network, in response to receiving the verification message.

Claims

1. A method for an automated configuration of an industrial controller unit, comprising: sending, from a server system, an instruction message and a verification token to a client device via a first communication network wherein the instruction message comprises information pertaining to a modification of an industrial controller unit, and wherein the verification token pertains to a completed modification of the industrial controller unit; receiving, at the server system, a verification message pertaining to the verification token, wherein the verification message is a message based on or employing the verification token received from the server system, and is adapted to signal to the server system the completed modification of the industrial controller unit; and providing, from the server system, an industrial program and/or a parameter for an industrial program to the industrial controller unit via a second communication network, in response to receiving the verification message.

2. The method according to claim 1, further comprising receiving, at the server system, an identification message pertaining to an identity of the industrial controller unit and providing the industrial program and/or the parameter for the industrial program to the industrial controller unit only in response to receiving the identification message.

3. The method according to claim 1 further comprising verifying an authorization and sending the instruction message and/or the verification token to the client device only upon verifying the authorization.

4. The method according to claim 1, further comprising detecting an operating state of the industrial controller unit and sending the instruction message and/or the verification token to the client device in response to detecting the operating state.

5. The method according to claim 1, wherein the verification token comprises a barcode.

6. The method according to claim 1, wherein the industrial program and/or the parameter for the industrial program is provided to the industrial controller unit automatically in response to receiving the verification message.

7. The method according to claim 1, further comprising selecting the industrial program and/or the parameter for the industrial program in accordance with the verification message, in particular from a database.

8. A method for an automated configuration of an industrial controller unit, comprising: receiving, at a client device, an instruction message and a verification token from a server system via a first communication network, wherein the instruction message comprises information pertaining to a modification of an industrial controller unit, and wherein the verification token pertains to a completed modification of the industrial controller unit; sending, from the client device, a verification message to the server system, wherein the verification message pertains to the verification token; and wherein the verification message is a message based on or employing the verification token received from the server system, and is adapted to signal to the server system the completed modification of the industrial controller unit, and is adapted to cause the server system to provide an industrial program and/or a parameter for an industrial program from the server system to the industrial controller unit via a second communication network.

9. The method according to claim 8, further comprising sending, from the client device, an identification message to the server system, wherein the identification message pertains to an identity of the industrial controller unit.

10. The method according to claim 8, further comprising triggering the controller unit to provide an identification message to the server system herein the identification message pertains to an identity of the industrial controller unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features and numerous advantages of the method and system according to the present invention will be best understood from a detailed description of preferred embodiments with reference to the drawings, in which:

(2) FIG. 1 is a schematic overview of an industrial control environment in which the method and system according to the present invention may be employed;

(3) FIG. 2 is a schematic illustration of a server system according to an embodiment;

(4) FIG. 3 is a schematic illustration of a client device according to an embodiment;

(5) FIG. 4 is a flow diagram illustrating a chain of communications between an industrial controller unit, server system, and client device according to a first embodiment;

(6) FIG. 5 is a flow diagram illustrating the communication chain between an industrial controller unit, server system, and client device according to a second embodiment;

(7) FIG. 6 is a flow diagram illustrating a communication chain between an industrial controller unit, server system, and client device according to a third embodiment employing a trigger message from the client device to the controller unit;

(8) FIG. 7 is a flow diagram illustrating a method for an automatic configuration of an industrial controller unit implemented on a server system according to an embodiment; and

(9) FIG. 8 is a flow diagram illustrating a method for an automatic configuration of an industrial controller unit implemented on a client device according to an embodiment.

DETAILED DESCRIPTION

(10) Methods and systems for an automated configuration of an industrial controller unit will now be described with reference to FIGS. 1 to 8 for the example of an industrial control environment 10 comprising a plurality of industrial controller units 12.sub.1 to 12.sub.5 that are connected to a server system 14 via a control network 16.

(11) With reference to FIG. 1, the industrial control environment 10 may be a factory environment, and each of the industrial controller units 12.sub.1 to 12.sub.5 may control a machine or tool or group of machines or tools 18.sub.1 to 18.sub.8 connected to the industrial controller units 12.sub.1 to 12.sub.5 in the industrial control environment 10. Each of the industrial controller units 12.sub.1 to 12.sub.5 may be equipped with their own processor and memory (not shown) and may run an industrial control program for controlling the associated machine or tool 18.sub.1 to 18.sub.8. The control program may be stored locally in the memory of the respective industrial controller unit 12.sub.1 to 12.sub.5, such as in the form of compiled machine code or ladder logic instructions. The industrial control program may run on the processor of the respective industrial controller unit 12.sub.1 to 12.sub.5, and may rely on control parameters stored locally in the respective memory, or provided remotely from the server system 14 via the control network 16. These parameters may be recipe parameters or other input variables required by the control program for operation of the respective machines or tools 18.sub.1 to 18.sub.8. Moreover, each of the industrial controller units 12.sub.1 to 12.sub.5 may generate output variables or log files, and may store them locally in memory or upload them to the server system 14 over the control network 16.

(12) The control network 16 may be any data network adapted for communication and data exchange back and forth between the industrial control units 12.sub.1 to 12.sub.5 and the server system 14, either wired or wireless or mixed. For instance, the control network 16 may be a local area network. If some of the industrial controller units 12.sub.1 to 12.sub.5 are located remotely, or distributed over a large area, the control network 16 could also be the internet.

(13) FIG. 1 shows a configuration with five industrial controller units 12.sub.1 to 12.sub.5, wherein each of the industrial controller units 12.sub.1 to 12.sub.5 controls between one and three machines 18.sub.1 to 18.sub.8. However, this is for illustration only, and in practical implementations the industrial control environment 10 may comprise a single industrial controller unit or any number of industrial controller units, adapted to control a single or any number of machines or tools. It is a particular advantage of the methods and systems according to the present disclosure that they can simplify a configuration or reconfiguration of a large number of industrial controller units 12.sub.1 to 12.sub.5 from a single server system 14.

(14) As can be further taken from FIG. 1, the control environment 10 additionally comprises a client device 20 that is connected to the server system 14 via a communication network 22.

(15) The client device 20 may be a communication device, such as a tablet computer or mobile phone. The client device 20 may be employed by operating personnel in the commissioning or maintenance of the industrial controller units 12.sub.1 to 12.sub.5, as will be described in more detail below.

(16) The communication network 22 may be a wired or wireless or mixed network. In some examples, the communication network 22 may be the internet.

(17) While FIG. 1 shows the control network 16 and the communication network 22 as separate networks, this is for illustration and ease of presentation only, and in other examples the control network 16 and the communication network 22 may be identical, or partially identical.

(18) A schematic illustration that shows an embodiment of the server system 14 in additional detail is given in FIG. 2.

(19) As can be taken from FIG. 2, the server system 14 comprises a server instruction unit 24, a server receiving unit 26, and a configuration unit 28.

(20) The server instruction unit 24 is adapted to send an instruction message and a verification token to the client device 20 via the communication network 22. The instruction message may comprise information pertaining to a modification of an industrial controller unit, such as a sequence of work steps that a user may need to follow in order to re-configure one of the industrial controller units 12.sub.1 to 12.sub.5, or to replace one of the industrial controller units 12.sub.1 to 12.sub.5 with a different industrial controller unit.

(21) The verification token may be employed by the client device 20 to generate a verification message that signals the completed modification. The server system 14 receives the verification message by means of the server receiving unit 26.

(22) For instance, the verification token may comprise a text message with a confirmation link that is sent from the server instruction unit to the client device 20 via the communication network 22. Once the operating personnel have successfully completed the modification of the industrial controller unit 12.sub.1 to 12.sub.5 according to the instruction message, the operating personnel may confirm by responding to the text message. For instance, if the modification relates to an exchange of a dysfunctional industrial controller unit by a replacement industrial controller unit 12.sub.1, the instruction message may provide detailed instructions for the exchange of the industrial controller unit and commissioning the new industrial controller unit 12.sub.1 step-by-step, and the operating personnel may generate the verification message to signal to the server system 14 that all the work steps in the instruction message have been followed, and that the industrial controller unit 12.sub.1 has been successfully added to the control environment 10.

(23) As can be taken from FIG. 2, the server receiving unit 26 is communicatively coupled to the configuration unit 28. Upon receiving the verification message, the server receiving unit 26 may trigger the configuration unit 28 to provide an industrial program and/or a parameter for an industrial program to the respective industrial controller unit, such as the industrial controller unit 12.sub.1, via the control network 16. In response to the verification message, the industrial controller unit 12.sub.1 is hence automatically provided with a dedicated industrial control program and/or corresponding parameters, without requiring additional interaction by the operating personnel.

(24) In some examples, the server system 14 may further comprise a database unit 30 that is communicatively coupled to the configuration unit 28. The database unit 30 may store industrial programs and/or parameters for industrial programs for a large number of industrial controller units 12.sub.1 to 12.sub.5. The configuration unit 28 may configure the respective industrial controller unit 12.sub.1 by selecting the corresponding industrial control program and/or parameters from the database unit 30.

(25) As can be further taken from FIG. 2, the server system 14 may additionally, in some examples, comprise a monitoring unit 32 that is coupled to the industrial controller units 12.sub.1 to 12.sub.5 by means of the control network 16. The monitoring unit 32 may monitor and detect an operating state of the industrial controller units 12.sub.1 to 12.sub.5. In response to a pre-determined condition being met, such as a malfunction occurring in one of the industrial controller units 12.sub.1 to 12.sub.5, the monitoring unit 32 may trigger the server instruction unit 24 to automatically send an instruction message to the client device 20. The instruction message may alert the operating personnel to replace the industrial controller unit 12.sub.1 to 12.sub.5 at which the malfunction occurred.

(26) In other examples, the server system 14 additionally comprises an authorization unit 34 that is adapted to verify an authorization before triggering the server instruction unit 24 to send the instruction message to the client device 20. The authorization unit 34 may hence control access to the server system 14, and may guarantee that only authorized personnel may start a configuration or re-configuration/update of one of the industrial controller units 12.sub.1 to 12.sub.5.

(27) For instance, authorization may be by means of password access, iris scan or other forms of identification.

(28) FIG. 2 shows the server instruction unit 24, server receiving unit 26, configuration unit 28, database unit 30, monitoring unit 32, and authorization unit 34 as components of a single integrated server system unit 14. However, this is for illustration only, and in some applications any of these units may be located remotely.

(29) FIG. 3 is a schematic illustration of a client device 20 according to an embodiment.

(30) As can be taken from FIG. 3, the client device 20 comprises a client receiver unit 36 adapted to receive the instruction message and the verification token from the server system 14 via the communication network 22.

(31) The client device 20 may be adapted to display the received instruction message and/or the verification token on a display device (not shown), such as a monitor of the client device 20. The operating personnel may follow the work steps prescribed in the instruction message to modify one of the industrial controller units 12.sub.1 to 12.sub.5.

(32) As can be further taken from FIG. 3, the client device additionally comprises a client verification unit 38. The client verification unit 38 may be adapted to send a verification message to the server system 14 via the communication network 22. The verification message may be received by the server receiving unit 26 and may signal to the server system 14 that the operating personnel has successfully completed the modification of the industrial controller unit 12.sub.1 to 12.sub.5.

(33) In some examples, the client verification unit 38 may generate the verification message when the operating personnel clicks on a link in a text message or an e-mail. In other examples, the client verification unit 38 may generate the verification message when the user scans a one- or two-dimensional barcode provided to him as part of the instruction message.

(34) As can be further taken from FIG. 3, in some examples the client device 20 may additionally comprise an identification unit 40. The identification unit 40 may be adapted to send an identification message to the server system 14 via the communication network 22, or may be adapted to trigger the controller unit 12.sub.1 to 12.sub.5 to provide an identification message to the server system via the control network 16.

(35) In some examples, the identification unit 40 may generate the identification message based on a user input of the operating personnel, such as based on input of an identification number that the operating personnel has read off the housing of the respective industrial controller unit 12.sub.1 to 12.sub.5.

(36) The identification message may comprise information pertaining to an identity of the industrial controller unit 12.sub.1 to 12.sub.5 that has been modified, and may hence assist the server system 14 in selecting the appropriate industrial program and/or parameters for the industrial controller unit 12.sub.1 to 12.sub.5 that has been modified.

(37) Even in examples in which the verification token or verification message already comprises an identification of the respective industrial controller unit 12.sub.1 to 12.sub.5, the additional identification message may allow the server system 14 to double check that the operating personnel has chosen the correct industrial controller unit 12.sub.1 to 12.sub.5, in accordance with the instructions provided in the instruction message. This is particularly helpful in the scenario in which the operating personnel is provided with a large number of instruction messages pertaining to a large number of industrial controller units 12.sub.1 to 12.sub.5, such as when setting up or commissioning the control environment 10.

(38) In other scenarios, only a single industrial controller unit 12.sub.1 to 12.sub.5 of the control environment 10 needs to be modified, such as to replace an industrial controller unit 12.sub.1 to 12.sub.5 that has become dysfunctional. In this scenario, it may be possible for the server system 14 to reliably identify the industrial controller unit 12.sub.1 to 12.sub.5 that has been modified by means of a network scan, and a separate identification by means of an identification message may not always be required.

(39) The schematic illustration of FIG. 3 shows the client receiver unit 36, client verification unit 38, and identification unit 40 as components of a single integrated client device 20. However, this is for illustration only, and one or several of these units may be provided remotely.

(40) FIG. 4 is a schematic diagram that shows a chain of communications between the server system 14, client device 20, and controller unit 12.sub.1 to 12.sub.5 when the respective controller unit 12.sub.1 to 12.sub.5 is automatically configured according to an example of the present disclosure. Time flow is from top to bottom in FIG. 4.

(41) The exemplary method starts with the server system 14 sending an instruction message 42 and a verification token 44 to the client device 20. FIG. 4 shows the instruction message 42 and the verification token 44 as separate messages. However, in other examples the instruction message 42 and the verification token 44 may also be combined into a single message, and may be sent simultaneously to the client device 20.

(42) As explained above with reference to FIGS. 1 to 3, the instruction message 42 comprises information pertaining to a modification of the respective industrial controller unit 12.sub.1 to 12.sub.5, and the verification token 44 pertains to a completed modification of the respective industrial controller unit 12.sub.1 to 12.sub.5.

(43) When the modification of the industrial controller unit 12.sub.1 to 12.sub.5 has been completed according to the instruction message 42, the client device 20 employs the verification total 44 to generate a verification message 46 and sends it to the server system 14. The verification message 46 signals to the server system 14 that the modification of the respective industrial controller unit 12.sub.1 to 12.sub.5 has been successfully completed by the operating personnel.

(44) In response to receiving the verification message 46, the server system 14 may provide an industrial control program 48, such as a compiled industrial control program or ladder logic instructions, to the respective controller unit 12.sub.1 to 12.sub.5.

(45) Alongside the industrial control program 48, the server system 14 may also provide parameters for the industrial control program 48 to the respective industrial controller unit 12.sub.1 to 12.sub.5.

(46) FIG. 5 shows an example of a flow diagram that generally corresponds to the example described above with reference to FIG. 4. However, according to the example of FIG. 5, the client device 20 sends an additional identification message 50 to the server system 14 alongside the verification message 46.

(47) As described above with reference to FIG. 3, the identification message 50 may contain information that allows the server system 14 to identify the industrial controller unit 12.sub.1 to 12.sub.5 that has been modified. The server system 14 may use this information to select the correct industrial program 48 and/or parameters for the industrial program 48 pertaining to the industrial controller unit 12.sub.1 to 12.sub.5 that has been modified.

(48) FIG. 6 is a schematic diagram illustrating a chain of communications between the industrial controller unit 12.sub.1 to 12.sub.5, the server system 14 and the client device 20 according to another example.

(49) The diagram of FIG. 6 generally corresponds to the diagram described above with reference to FIG. 5. However, instead of the identification message 50 to the server system 14, the client device 20 sends a trigger message 52 to the industrial controller unit 12.sub.1 to 12.sub.5 The trigger message 52 triggers the industrial controller unit 12.sub.1 to 12.sub.5 to send an identification message 50′ to the server system 14. Similar to the identification message 50, the identification message 50′ comprises information pertaining to the identity of the respective industrial controller unit 12.sub.1 to 12.sub.5, and helps the server system 14 to select the correct industrial program 48 pertaining to the respective industrial controller unit 12.sub.1 to 12.sub.5.

(50) FIG. 7 is a flow diagram illustrating a method for an automated configuration of an industrial controller from the perspective of a server system.

(51) In a first step S10, the server system sends an instruction message and a verification token to a client device via a first communication network. The instruction message comprises information pertaining to a modification of an industrial controller unit, and the verification token pertains to a completed modification of the industrial controller unit.

(52) In a second step S12, the server system receives a verification message pertaining to the verification token.

(53) In a third step S14, the server system provides an industrial program and/or a parameter for an industrial program to the industrial controller unit via a second communication network, in response to receiving the verification message in step S12.

(54) FIG. 8 is a schematic illustration of an example of a method for an automated configuration of an industrial controller unit from the complementary perspective of a client device.

(55) In a first step S20, the client device receives an instruction message and a verification token from a server system via a first communication network. The instruction message comprises information pertaining to a modification of an industrial controller unit, and the verification token pertains to a completed modification of the industrial controller unit.

(56) In a second step S22, the client device sends a verification message to the server system, wherein the verification message pertains to the verification token.

(57) The description of the embodiments and the Figures merely serves for illustrating examples of the invention and the numerous advantages resulting therefrom, but should not be understood to imply any limitation.

REFERENCE SIGNS

(58) 10 control environment 12.sub.1-12.sub.5 industrial controller units 14 server system 16 control network 18.sub.1-18.sub.8 machines/tools 20 client device 22 communication network 24 server instruction unit 26 server receiving unit 28 configuration unit 30 database unit 32 monitoring unit 34 authorization unit 36 client receiver unit 38 client verification unit 40 identification unit 42 instruction message 44 verification token 46 verification message 48 industrial program 50, 50′ identification message 52 trigger message