Using Cyber PLC to Link Physical Operations with Cyber Control Decisions

Abstract

The Manufacturing Control System (MCS) is the control core of modern automated manufacturing systems. As today’s devices become more automated, expectations for intelligent MCS (iMCS) are growing. Traditional MCS architectures based on rigid supervisory control and data acquisition (SCADA), such as MT-Link, face difficulties in meeting the expectations. The iMCS is considered the plant’s control system and can handle dynamic events occurring in the manufacturing system. With iMCS, manufacturing systems are flexible, powerful and adaptable to the interferences.This study introduces the architecture and application of iMCS. Within them, in addition to the Cyber PLC, edge computing, fog computing and cloud computing are the backbone. By taking advantage of the four complementary technologies, today’s physical PLCs can be replaced by Cyber PLC. With Cyber PLC, there is no need to translate the messages of different protocols from equipment. Data loss, overcrowded network transmissions, and exchanges on multiple databases can also be improved in the distributed collaborative manufacturing systems. With Cyber PLC, it is expected that the traditional dispersed physical PLC control elements over factories will no longer needed. Maintenance and management of MCS will be much improved.