Data losses and synchronization according to delay in PLC-based industrial automation systems

PLC (Programmable Logic Controllers) based data collection is integral to industrial automation and data acquisition processes. The pipeline – between the device and the database – is a complex system with many components and often causes some time delay, due to the synchronization and the applied hardware and software components. This delay can also lead to data loss on the database site. In this study, we aimed to examine this problem connected to the synchronized behavior of four counter networks within the TIA software for PLCs, particularly focusing on the implications of a 1 Hz (Hz) clock frequency on counter synchronization. Meticulous experiments were conducted and the integration of Node-RED, as an instrumental tool in industrial automation, facilitated counter-behavior monitoring. Recorded values of counter and timestamps were meticulously stored in four separate databases (MSSQL, MySQL, MongoDB, and Apache Cassandra) for comprehensive data analysis. Throughout the experiments, inconsistencies in the counter values were encountered, leading to the discovery of missing values that varied across the ten tests. To detect the reason, a unique delay calculation method was developed. According to our results, we were able to do post-synchronization with millisecond-level accuracy. It can help reveal the missing values that depend on the Node-RED and the PLC cycle time differences. •Systematic data analysis in the case of SQL and NoSQL communication with PLC.•Created a predictive model for anticipating missing values during data transfer from PLC based on the time differences.•Introduce the possible compensation values – as a key factor – to determine the delays.•Create a unique method that can determine the un-synchronization between PLC and database according to the collected data.•Provided valuable insights for data transmission and synchronization in industry, to enhance efficiency and decision-making.