Have PLC Controller Listen/Send Custom TCP Packets?

Question

I would like to be able to communicated with PLC controllers, so that I can send and receive custom commands on the PLC.

My idea of being able to do this was to have a TCP listener on the PLC that could read TCP incoming packets on a specific port, and execute routines based on the commands in the packets. It could also send information back via TCP/IP.

This would allow me to write software in multiple languages such as C#, PHP, JavaScript, etc. so that software can be used on any platform such as Windows, iOS, Android, etc. to issue commands to the PLC. This would also mean you do not need the PLC software (which can be costly) to view or control the PLC.

I am not a PLC programmer, so I do not know if PLC has the capability of sending and receive custom TCP packets. I would like to know that a) if it is possible b) how feasible it would be to do this and c) what exactly I should research so that I can accomplish this.

Thanks.

Answer 1

It sounds a bit like reinventing the wheel. You want to make something like KepServerEX?

http://www.kepware.com/kepserverex/

There are also two things to consider - one is the ability to interface with the PLC to share data (ie: for a custom HMI) and the other is to program the PLC. For the latter you still need the control software from the manufacturer unless you're willing to reverse engineer and re-write it from the ground up.

Keep in mind, also, that PLCs don't work the same way that other software does. There are no functions or procedures or classes or objects or even really any "commands", per se. A PLC is a system which executes a continuous fixed program of mostly raw logic rules and calculations. A typical interface to an HMI involves reading and writing directly to/from logic bits and word data (ie:hardware memory locations) which represent the current state of the machine. OPC already does this just fine so I'm not quite sure what you're going for.

If you're looking for a cheap/free alternative to a full commercial package, something here may work for you :

http://www.opcconnect.com/freesrv.php

Answer 2

If I understand correctly, when referred to "Run/Stop" you mean for the PLC to 'Start' or 'Stop' scanning the code and updating its I/O. If this is the situation, it would be perfectly suitable to add a Scan_If_On bit (which will be written by a TCP Command) in parallel connection with the "Start" bit controlled by the HMI. This way, there will be 2 forms of "Starting" the process controlled by the PLC. HMI and TCP.