Synchronized time-series data and execution trace for debugging programmable logic controllers

A non-transitory computer readable medium storing instructions thereon that, when executed on a computing system, cause the computer system to carry out operations including:

• synchronizing sensor data from an industrial process with program trace data from a control program executed by a programmable logic controller (PLC) controlling the industrial process, wherein the synchronizing comprises:
• executing a control program, using the PLC, to control industrial equipment and cause physical responses in the industrial equipment;
• receiving sensor data based on the physical responses in the industrial equipment, from a plurality of sensors, wherein the plurality of sensors include at least one sensor configured to provide streaming data, and one or more additional sensors configured to sense physical data;
• recording program trace data from the control program and sensor data from each of the plurality of sensors, wherein the program trace data and the sensor data are time-stamped, and wherein the sensor data is periodically recorded in a capture period;
• synchronizing instances of the time-stamped program trace data and instances of the time-stamped sensor data, wherein the synchronizing comprises determining, for a given instance of the time-stamped program trace data, that the given instance of the program trace data is within a time period having an upper boundary corresponding to a next consecutive given instance of the time-stamped program trace data and a lower boundary defined by a difference between the next consecutive given instance of the time-stamped program trace data and the capture period of sensor data for a corresponding one of the plurality of sensors;
• linking an instance of the time-stamped sensor data within upper and lower boundaries to the time-stamped program trace data within the upper and lower boundaries;
• presenting instances of the synchronized data to a user via a debugger interface to enable a user to debug the control program in order to generate a debugged control program;
• and
• executing the debugged control program.

A system for controlling an automated industrial process, the system comprising:

• a programmable logic controller (PLC) configured to execute a control program to control industrial equipment carrying out the industrial process, and further configured to cause physical responses in the industrial equipment;
• a computer system coupled to the PLC, wherein the computer system is configured to:
• receive, from a plurality of sensors, sensor data based on the physical responses in the industrial equipment, wherein the plurality of sensors include at least one sensor configured to provide streaming data, and one or more additional sensors configured to sense physical data;
• record program trace data from the control program and sensor data from each of the plurality of sensors, wherein the program trace data and the sensor data are time-stamped, and wherein the sensor data is periodically recorded in a capture period;
• synchronize instances of the time-stamped program trace data and instances of the time-stamped sensor data, wherein the synchronizing comprises:
• determining, for a given instance of the time-stamped program trace data, that the given instance of the program trace data is within a time period having an upper boundary corresponding to a next consecutive given instance of the time-stamped program trace data and a lower boundary defined by a difference between the next consecutive given instance of the time-stamped program trace data and the capture period of sensor data for a corresponding one of the plurality of sensors;
• and
• linking an instance of the time-stamped sensor data within upper and lower boundaries to the time-stamped program trace data within the upper and lower boundaries;
• and
• present a debugging interface for debugging the control program to generate a debugged control program, wherein presenting the debugging interface includes presenting instances of the synchronized data to a user via a debugger interface, wherein the PLC is further configured to execute the debugged control program.