Software Architecture and Framework for Programmable Automation Controller: A Systematic Literature Review and A Case Study

Abstract: Background. PAC controller is a strengthened version of PLC controller. Its function is very similar, but its essence and construction are different. PLC and PAC have many successful applications in the field of industrial automation control. There is a lot of literature about the software architecture of PLC control system. However, there is almost no relevant literature on software architecture based on PAC control system. A well-performing and stable automatic control system is indispensable to the design and development of suitable software architecture. The quality and pattern of software architecture can even affect the stability and efficiency of the control system. Objectives. Based on these problems, we defined two primary objectives. The first is to investigate the architecture of some existing large industrial control systems, to analyze and summarize the scenarios and advantages and disadvantages of these architectural patterns. The second, based on the results of effort for the first objective, we want to propose and design a set of automated control solution architecture model based on PAC control system, which is implemented and applied in a printing house. In the process, we sum up the challenges and obstacles encountered in implementing the solution and provide some guidance or reference for those involved in the field. Methods. For the first objective, we used a systematic literature review to collect data about existing ICS architecture. Concerning the second objective, a case study was conducted in a printing house in Karlskrona Sweden, in the study, we proposed a software architecture model suitable for PAC automation control system. Then, we developed and tested the automation control system and summarized some challenges and obstacles in the process of the implementation. Results. The existing ICS (Industrial Control System) architecture models and critical problems and challenges in the implementation of ICS are identified. From the existing literature, we have summarized five commonly used large industrial control system architecture models, which are mainly using composite structures, that is, a combination of multiple architecture patterns. Also, some critical problems in the industrial control system, such as information security, production reliability, etc. are also identified. In the case study, we put forward an automatic control solution for Printing House based on SLR results. We designed the hardware deployment architecture of the system and the software control architecture. Generally speaking, this architecture is based on C/S architecture. In the development of client, we adopt the popular MVC architecture mode. In the longitudinal view of the whole system, an extended hierarchical architecture model is adopted. In the core control system, we adopt the modular architecture design idea. The whole control system is composed of 6 parts, four subsystems of PAC terminal, one server-side program and one client program. After a long time, development and test, our system finally goes online for the production, and its production efficiency is improved compared with the old system. Its expansion functions, such as Production Report and Tag Print, are deeply satisfying for the customers. Conclusions. In this research, we summarize and compare the advantages and disadvantages of several commonly used industrial control systems. Besides, we proposed a software architecture model and developed an automation control system based on PAC. We fill the gap that there is a lack of studies about the software architecture about the implementation of the automation control system based on PAC. Our result can help software engineers and developers in ICS fields to develop their own PAC based automation control system.