Artificial intelligence (AI) companions for function blocks in a programmable logic controller (PLC) program for integrating AI in automation

A method of controlling an automation process, comprising:

• pairing an artificial intelligence (AI) companion to a function block of a programmable logic controller (PLC) control program, wherein the function block is a designated control function associated with at least one input and at least one output;
• training the AI companion during simulation of inputs while running the PLC control program for a plurality of cycles during development of the function block;
• validating, by a runtime component, the function block;
• executing the PLC control program using the AI companion for controlling the designated control function without the function block;
• optimizing an algorithm of the AI companion during a runtime operation;
• monitoring, by the runtime component, a programmable logic controller (PLC) wherein on a condition of malfunction, swapping the control of the designated control function from the AI companion to the function block, wherein AI companion for function blocks and groups of function blocks in PLC programs are provided such that the AI companion is highly integrated with a PLC program, and wherein an automatic generation of AI companions that are integral to function blocks is provided and AI companions get data in and out directly from a process image.

An intelligent programmable logic controller (PLC) comprising:

• a processor configured to execute according to a scan cycle;
• a volatile computer-readable storage medium comprising a process image area;
• a non-volatile computer-readable storage medium;
• and
• a plurality of controller components executed by the processor according to the scan cycle, the plurality of controller components comprising:
• a data transfer component configured to update the process image area during each scan cycle with contents comprising automation system data;
• a function block comprising at least one input and at least one output, wherein the function block is configured to control a designated control function of a control program;
• an artificial intelligence (AI) companion configured to perform steps comprising:
• using the at least one input and the at least one output to train the associated AI companion, and
• once the associated AI companion is fully trained, the associated AI companion is configured to take over an original function block and perform an operation with some unknown inputs;
• and
• a runtime component for executing a runtime operation of the PLC, the runtime operation comprising:
• enhancing a functionality of a plurality of function blocks with a plurality of artificial intelligence (AI) companions in a passive state of monitoring or with the plurality of artificial intelligence (AI) companions in an active state of over taking control, wherein AI companion for function blocks and groups of function blocks in PLC programs are provided such that the AI companion is highly integrated with a PLC program, and wherein an automatic generation of AI companions that are integral to function blocks is provided and AI companions get data in and out directly from a process image.