Method for consistent storage of data in an industrial controller

• US 9,852,152 B2
• Filed: 10/24/2016
• Issued: 12/26/2017
• Est. Priority Date: 07/30/2001
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kay, James J., Johnston, David Allen, Urdaneta, Shelly Lynn, Siegel, Stuart Blair
• Primary Examiner(s): Nguyen, Phong H
• Application Number:
  US15/332,520
• Publication Number:
  US 20170039221A1
• Time in Patent Office: 428 Days
• Field of Search: 707827
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: G05B 2219/13076 Interprete in pc a ladder diagram, use of sequence engine
• CPC Class Codes: G05B 2219/15101 Personal computer pc and plc, slot plc, same kernel
• CPC Class Codes: G05B 2219/15115 Pc serves as plc, programming panel, monitoring panel
• CPC Class Codes: G05B 2219/23301 Load program from file system of a controller
• CPC Class Codes: G05B 2219/31457 Factory remote control, monitoring through internet
• CPC Class Codes: G05B 2219/34279 Pc, personal computer as controller
• CPC Class Codes: G06F 16/119 Details of migration of file systems migration mechanisms in storage systems G06F3/0647
• CPC Class Codes: G06F 16/182 Distributed file systems
• CPC Class Codes: H04L 67/01 Protocols
• CPC Class Codes: H04L 67/1097 for distributed storage of data in networks, e.g. transport arrangements for network file system [NFS], storage area networks [SAN] or network attached storage [NAS]

Abstract

A system and method for employing a file system and file system services on the industrial controller. The file system allows industrial control programs to implement many functions previously performed within the industrial control program and stored in the same memory as the industrial control program. An execution engine is provided that interprets instructions included in an industrial control program. The instructions utilize services in the file system for including user defined routine files loaded from local or remote locations, to load and unload recipe files from local and remote locations, to log and retrieve measured data and trend data to files at local or remote locations, to select different operating systems and to select a running program from a plurality of running programs utilizing the file system.

Claims

1. A method, comprising:

sending, by industrial controllers using respective file system services, data collected by the industrial controllers to a remote server device via a web service, wherein the industrial controllers respectively control at least one automation device or process;

storing, by the remote server device, the data as aggregated data on a memory of the remote server device;

analyzing, by an auditing application executing on the remote server device, the aggregated data;

retrieving, via the web service by a subset of the industrial controllers using a corresponding at least one of the respective file system services, a subset of the aggregated data;

storing, by the subset of the industrial controllers, the subset of the aggregated data on one or more local memories of the subset of the industrial controllers;

retrieving, by the subset of the industrial controllers, an executable routine file from the remote server device or from another server device via the web service;

storing, by the subset of the industrial controllers, the executable routine file on the one or more local memories of the subset of the industrial controllers; and

executing, by the subset of the industrial controllers, the executable routine file.

2. The method of claim 1, further comprising sending, by the remote server device to a subset of the industrial controllers, selection data via the web service, wherein the selection data invokes a selected program, of a plurality of application programs stored on the subset of the industrial controllers, for execution on the industrial controller.

3. The method of claim 1, further comprising, in response to receipt, by the subset of the industrial controllers, of selection data sent by a web browser application via the web service to one or more of the file system services, initiating execution of a selected control program, of a plurality of control programs stored on the subset of the industrial controllers, identified by the selection data.

4. The method of claim 1, further comprising retrieving, by the subset of the industrial controllers using one or more of the file system services, a recipe file from the remote server device or from another server device via the web service.

5. The method of claim 4, further comprising:

loading, by the subset of the industrial controllers, at least one process parameter defined by the recipe file to one or more local memories of the subset of the industrial controllers; and

executing, by the subset of the industrial controllers, a control program in accordance with the at least one process parameter.

6. The method of claim 1, further comprising retrieving, by the subset of the industrial controllers, an operating system file from the remote server device or from another server device via the web service.

7. The method of claim 1, wherein a portion of the data comprises trend data generated by the subset of the industrial controllers or measured data obtained by the subset of the industrial controllers.

8. The method of claim 1, wherein the sending comprises sending at portion of the data in response to execution, by the subset of the industrial controllers, of a control program instruction that invokes one or more of the file system services implemented on the subset of the industrial controllers.

9. The method of claim 8, wherein the control program instruction is a ladder logic instruction.

10. A system, comprising:

a server device comprising a local memory and a processor, the server device configured to communicate with industrial controllers through a public network via a web service, the industrial controllers respectively controlling an industrial device or process, wherein

the server is configured to aggregate data received from the industrial controllers via the web service to yield aggregated data, and to perform auditing analysis on the aggregated data to yield an analysis result,

the data is sent to the server device by the industrial controllers via the web service using respective file system services,

the aggregated data is accessible to the industrial controllers via the web service, and

the server device is further configured to store one or more executable routine files, and the one or more executable routine files are accessible to the industrial controllers via the web service.

11. The system of claim 10, wherein the server device is further configured to send, to a subset of the industrial controllers, selection data via the web service, wherein the selection data causes one or more of the file system services to invoke a selected program, of a plurality of application programs stored on the subset of the industrial controllers, for execution on the subset of the industrial controllers.

12. The system of claim 10, wherein the server device is further configured to store one or more recipe files, and wherein the one or more recipe files are accessible to the industrial controllers via the web service using the respective file system services.

13. The system of claim 10, wherein the server device is further configured to store one or more operating system files, and wherein the one or more operating system files are accessible to the industrial controllers via the web service.

14. The system of claim 10, wherein the data comprises at least one of time-series data generated by a subset of the industrial controllers or measured data obtained by the subset of the industrial controllers.

15. An industrial controller comprising:

a memory;

an execution engine; and

a file system storable in the memory and comprising a file system service;

wherein

the file system service is configured to, in response to execution of a control program instruction by the execution engine, send a set of data generated by the industrial controller to a remote server device via a web service,

the remote server device is configured to aggregate the set of data with other data received from one or more other industrial controllers to yield aggregated data and to perform an audit analysis on the aggregated data,

the file system service is further configured to retrieve a subset of the aggregated data from the remote server device via the web service and to store the subset of the aggregated data on a memory,

the file system service is further configured to retrieve, from the remote server device via the web service, an executable routine file stored on the remote server device and store the executable routine file on a local memory of the industrial controller, and

the execution engine is configured to execute the executable routine file to facilitate control of an automation device or process.

16. The industrial controller of claim 15, wherein the file system service is further configured to

receive, from the remote server device via the web service, selection data identifying a control program of a set of control programs stored on the memory, and

in response to receipt of the selection data, invoke the control program for execution on the industrial controller.

17. The industrial controller of claim 15, wherein the file system service is further configured to

retrieve, from the remote server device via the web service, a recipe file stored on the remote server device, and

retrieve, from the recipe file, one or more process parameters defined by the recipe file, and

wherein the execution engine is further configured to execute a control program in accordance with the one or more process parameters.

18. The industrial controller of claim 15, wherein the file system service is configured to send the set of data to the remote server device in response to execution, by the execution engine, of a control program instruction that causes the file system service to send the set of data.

19. The industrial controller of claim 15, wherein the file system service is further configured to, in response to receipt via the web service of selection data identifying a program of a plurality of application programs stored on the memory, execute the program.

20. The industrial controller of claim 15, wherein the file system service is configured to retrieve, via the web service, an operating system file from the remote server device or another remote device and to load the operating system file.