Method and system for data routing in distributed control system

Abstract

Disclosed is a method (100) and a system for data routing in a distributed control system (DCS) (300). The method including implementing a plurality of virtual connectors (VCs) (310) configured to interface between one or more communication channels (312) of the DCS and one or more instrument signals (314). The method further comprises monitoring operational parameters for the DCS. The method further comprises determining, by a data routing module (324), signal-to-channel assignments based on the operational parameters for the DCS, with each signal-to-channel assignment designating at least one of the plurality of VCs to interface between specific communication channel (s) of the DCS and specific instrument signal (s). The method further comprises communicating, by the data routing module, the signal-to-channel assignments to the plurality of VCs and a command centre (326). The method further comprises executing, by the plurality of VCs and the command centre, the signal-to-channel assignments to dynamically adjust signal-to-channel connections within the DCS.

Description

[0001] METHOD AND SYSTEM FOR DATA ROUTING IN DISTRIBUTED CONTROL SYSTEM

[0002] DESCRIPTION

[0003] The present invention relates to the field of distributed control systems (DCS) used in industrial processes. Specifically, the present invention relates to methods and systems for optimizing data routing within such control systems through intelligent channel assignment and management.

[0004] In industrial automation, a distributed control system (DCS) facilitates complex processes across various sectors. These systems utilize both analog and digital modules to process raw input values from field instruments to a control hub, where these values are then processed and visualized on Human-Machine Interfaces (HMI) . The DCS provides precision and reliability, ensuring the seamless continuation of industrial operations. However, a major challenge is that the DCS systems can suffer from channel malfunctions. When channels that carry critical signal data fails, the corresponding values from that channel are unable to be fetched by the DCS. This can lead to unintended tripping of drives based on the dependent logic implemented in the DCS as control philosophy. Such failures in channels will also result in loss of critical parameters, subsequently affecting the power generation capacity, and directly impacting productivity and safety .

[0005] Conventionally, the resolution of such malfunctions has been a reactive process. In a running plant, if a process values quality gets poor or bad and stops receiving electrical signals from the field, the operator reports it to the shi ft engineer . The engineer then checks the module status and identifies that the channel i s faulty . Once the engineering team receives work-permit approval from management , they proceed to remove the terminated cables from the faulty channel and re-plug them into an available spare channel on the same module . In case there is no spare channel available on the same card, the engineer will need to reorganize the wiring and connect it to another card that has an available channel . Additionally, the engineer must update the new channel details in the engineering workstation . Thi s ensures that the af fected proces s value can be retrieved again from the newly wired channel . Until the engineer manually rewires the cables to the available spare channel and reconfigures it in the engineering station, the proces s value will remain in a "BAD" state impacting the proces s logics , hence operations .

[0006] However, such conventional solution has inherent limitations . During the re-configuration proces s , as the proces s value i s unavailable, there is high risk of di sruption to operations of the DCS . In the worst-case scenario , thi s dis ruption could lead to a complete shutdown, ranging from a single motor to the entire proces s plant drives due to implemented control philosophy . Further, the manual reconfiguration of wiring and channel detail s has the risk of human error . Moreover, in scenarios where spare channels are not readily available , the solution escalates into a more complex challenge involving the reorganization of wiring or the laying of new cables , which is a time-consuming and costly undertaking . Therefore , there is a need for a solution that may provide efficient and adaptive method for data routing that not only mitigates the impact of channel malfunctions but al so enhances the overall integrity and responsivenes s of the control system . Such a solution would represent a s ignificant leap forward in the domain of industrial automation, aligning with the trajectory of progres s and the imperatives of operational excellence .

[0007] The present invention seeks to addres s these shortcomings by providing a solution which offers efficient and adaptive method for data routing that mitigates the impact of channel malfunctions , and also enhances the overall integrity and responsivenes s of the control system . The present invention implements data routing within a DCS by implementing a system of Virtual Connectors (VCs ) , a data routing module, and a dynamic data acquisition module . The VCs serve as intermediaries between communication channel s and instrument signal s of the DCS , facilitating flexible and efficient data exchange . The data routing module, guided by operational parameters monitored from a command centre, determines optimal signal-to-channel as signments , dynamically adjusting these as signments as system conditions evolve . Thi s architecture ensures adaptive management of data flow within the DCS , signi ficantly enhancing system reliability and operational efficiency .

[0008] The obj ect of the present invention is achieved by a method for data routing in a di stributed control system (DCS ) . The method comprises implementing a plurality of virtual connectors (VCs ) . Herein, each VC configured to interface between one or more communication channel s of the DCS and one or more instrument signals . The method further comprises monitoring, by a data acquisition module from a command centre , operational parameters for the DCS . The operational parameters comprises information about one or more of available communication channels of the DCS , current statuses of the communication channels of the DCS , priorities for the instrument signals , specific interests for communication channels vis-a-vi s the instrument signals , and loading percentages of the communication channels of the DCS . The method further compri ses determining, by a data routing module , signal-to-channel as signments based on the operational parameters for the DCS , with each signal-to-channel as s ignment designating at least one of the plurality of VCs to interface between specific communication channel ( s ) of the DCS and speci fic instrument signal ( s ) . The method further comprises communicating, by the data routing module, the signal-to-channel as signments to the plurality of VCs and the command centre . The method further comprises executing, by the plurality of VCs and the command centre, the signal-to-channel as signments to dynamically adjust signal-to- channel connections within the DCS .

[0009] In one or more embodiments , the method also comprises proces sing, by the data routing module, the information about the current statuses of the communication channels of the DCS to determine presence of one or more faulty communication channels of the DCS . The method further comprises adjusting the s ignal-to-channel connections to as s ign one or more spare channels from the available communication channels of the DCS for the instrument signals corresponding to the one or more faulty communication channels of the DCS . In one or more embodiments , the method al so comprises proces sing, by the data routing module, the information about the priorities for the instrument signal s to determine high-priority instrument signals . The method further comprises prioritizing the as signment of the one or more spare channels from the available communication channels of the DCS to the high-priority instrument signals from the instrument signals corresponding to the one or more faulty communication channels of the DCS .

[0010] In one or more embodiments , the method also comprises proces sing, by the data routing module, the information about the loading percentages of the communication channels of the DCS to determine presence of one or more overloaded communication channels of the DCS . The method further comprises adjusting the s ignal-to-channel connections to as s ign one or more spare channels from the available communication channels of the DCS for the instrument signals corresponding to the one or more overloaded communication channel s of the DCS .

[0011] In one or more embodiments , the method also comprises proces sing, by the data routing module, the information about the specific interests for communication channels vis-a-vi s the instrument signals to determine particular communication channel ( s ) of the DCS for speci fic instrument signal ( s ) . The method further comprises adjusting the signal-to-channel connections to bind the particular communication channel ( s ) of the DCS for the specific instrument signal ( s ) .

[0012] In one or more embodiments , the step of executing, by the plurality of VCs and the command centre , the signal-to-channel as signment s to dynamically adjust signal-to-channel connections within the DCS comprises automatically reconfiguring the connection ( s ) between the one or more communication channels of the DCS and the one or more instrument s ignal s via the plurality of VCs based on the signal-to-channel as s ignments . In one or more embodiments , the method further comprises sending an acknowledgement by the plurality of VCs to the data routing module confirming the reconfiguration of the connection ( s ) between the one or more communication channels of the DCS and the one or more instrument signals . In one or more embodiment s , the method further comprises configuring, by the data routing module, the command centre to update details about the reconfiguration of the connection ( s ) between the one or more communication channels of the DCS and the one or more instrument s ignal s via the plurality of VCs .

[0013] The obj ect of the present invention is also achieved by a system comprising one or more proces s ing units and a memory unit communicatively coupled to the one or more proces sing units . Herein, the memory unit comprises a data routing module stored in the form of machine-readable instructions executable by the one or more proces sing units . Herein, the data routing module i s configured to perform aforementioned method steps for data routing in a distributed control system (DCS ) .

[0014] The ob ject of the present invention is further achieved by a computer program product , having machine-readable instructions stored therein, that when executed by the one or more proces sing unit s , cause the one or more proces sing units to perform aforementioned method steps .

[0015] Still , other aspects , features , and advantages of the invention are readily apparent from the following detailed description, simply by illustrating a number of particular embodiments and implementations , including the best mode contemplated for carrying out the invention . The invention is also capable of other and different embodiments , and it s several details may be modified in various obvious respects , all without departing from the scope of the invention . Accordingly, the drawings and description are to be regarded as illustrative in nature , and not as restrictive .

[0016] A more complete appreciation of the present invention and many of the attendant aspects thereof will be readily obtained as the same becomes better understood by reference to the following description when cons idered in connection with the accompanying drawings :

[0017] FIG 1 is a flowchart of a method for data routing in a distributed control system (DCS ) , in accordance with one or more embodiments of the present invention ;

[0018] FIG 2 is a schematic representation of a system for data routing in the DCS , in accordance with one or more embodiments of the present invention;

[0019] FIG 3 is a schematic representation of an architecture of the DCS , in accordance with one or more embodiments of the present invention;

[0020] FIG 4 is a schematic representation of a proces s for data routing in the DCS , in accordance with one or more embodiments of the present invention;

[0021] FIG 5 is an exemplary configuration of the DCS , in accordance with one or more embodiments of the present invention;

[0022] FIG 6 is a first use-case in which an is sue is identified with one of communication channels in the exemplary configuration of the DCS of FIG 5 , in accordance with one or more embodiments of the present invention; FIG 7 is a second use-case in which an is sue i s identified with multiple communication channels in the exemplary configuration of the DCS of FIG 5 , in accordance with one or more embodiments of the present invention;

[0023] FIG 8 is a third use-case which outlines procedure for prioritized channel as signment in case of channel failures in the exemplary configuration of the DCS of FIG 5 , in accordance with one or more embodiments of the present invention; and

[0024] FIG 9 is a fourth use-case which provides a scenario where spare communication channels are strategically reserved for high-priority instrument signals in the exemplary configuration of the DCS of FIG 5 , in accordance with one or more embodiments of the present invention .

[0025] Various embodiments are described with reference to the drawings , wherein like reference numerals are used to refer to like element s throughout . In the following description, for the purpose of explanation, numerous specific details are set forth in order to provide thorough understanding of one or more embodiments . It may be evident that such embodiments may be practiced without these specific details .

[0026] Examples of a method, a system, and a computer-program product for data routing in a distributed control system (DCS ) are dis closed herein . In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiment s of the invention . It is apparent , however, to one skilled in the art that the embodiments of the invention may be practiced without these specific details or with an equivalent arrangement. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the embodiments of the invention.

[0027] As used herein, the distributed control system (DCS) refers to an integrated automation system used to control complex, large-scale industrial processes. It is a networked system where control elements are not centralized but distributed throughout the system. This distribution of control elements allows for efficient process management, greater redundancy, and improved reliability. The DCS may include Input / output (I / O) field devices, including be sensors or actuators placed throughout the industrial plant to monitor real-time conditions and effect changes to the process; programmable logic controllers (PLCs) or other types of industrial-grade computers that process data from I / O field devices and issue control commands; Human-Machine Interface (HMI) which allows human operators to interact with the DCS, providing real-time data visualizations, alerts, and control panels for process management; and a communication network which enables data exchange between controllers, I / O devices, and HMIs.

[0028] Data routing, within the present context, pertains to a process by which data signals are transmitted from one part of the DCS to another. It involves the path that process data takes from the field devices through the I / O channels to the controllers and eventually to the HMI for display and interaction. Data routing involves logic-based signal pathways that determine how data is processed and prioritized within the system. In present embodiments, data routing is facilitated by virtual connectors (VCs ) which serve as dynamic, software-defined pathways that can be adjusted in real-time for optimal data flow . Thi s introduces flexibility and adaptability in how signal routes are configured, allowing for an intelligent distribution of data based on current system demands and priorities .

[0029] Referring to FIG 1 , illustrated is a flowchart of a method (as represented by reference numeral 100 ) for data routing in the DCS , in accordance with an embodiment of the present invention . The method 100 provides a framework where virtual connectors serve as interfaces between communication channels and instrument signals . Operational parameters are continuously monitored, forming the basi s upon which signal-to-channel as signments are determined . These as s ignments are communicated to both the virtual connectors and a centralized command centre , ensuring that adjustments to signal-to-channel connections are executed throughout the DCS , hence maintaining the integrity and continuity of the control proces s .

[0030] Referring to FIG 2 , illustrated is a block diagram of a system 200 for data routing in the DCS , in accordance with one or more embodiments of the present invention . It may be appreciated that the system 200 described herein may be implemented in various forms of hardware, software, firmware, special purpose proces sors , or a combination thereof . One or more of the present embodiments may take a form of a computer program product comprising program modules acces sible from computer-usable or computer-readable medium storing program code for use by or in connection with one or more computers , proces sors , or instruction execution system . For the purpose of this description, a computer-usable or computer- readable medium may be any apparatus that may contain, store , communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus , or device . The medium may be electronic, magnetic, optical , electromagnetic, infrared, or semiconductor system (or apparatus or device ) or a propagation mediums in and of themselves as signal carriers are not included in the definition of physical computer- readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette , random acces s memory (RAM) , a read only memory (ROM) , a rigid magnetic disk and optical disk such as compact disk read-only memory ( CD-ROM) , compact disk read / write, and digital versatile disc (DVD ) . Both proces sors and program code for implementing each aspect of the technology may be centralized or distributed (or a combination thereof ) as known to those skilled in the art .

[0031] In an example , the system 200 may be embodied as a computer-program product programmed for digitalizing and analysing the engineering diagram for the industry environment . The system 200 may be incorporated in one or more phys ical packages (e . g . , chips ) . By way of example , a physical package includes an arrangement of one or more materials , components , and / or wires on a structural as sembly (e . g . , a baseboard) to provide one or more characteristics such as physical strength, conservation of s ize, and / or limitation of electrical interaction . It is contemplated that in certain embodiments the computing device may be implemented in a single chip . As illustrated, the system 200 includes a communication mechanism such as a bus 202 for pas sing information among the component s of the system 200 . The system 200 includes one or more proces sing units 204 and one or more memory units 206 . Herein, the memory unit 206 is communicatively coupled to the processing unit 204. In an example, the memory unit 206 may be embodied as a computer readable medium on which program code sections of a computer program are saved, the program code sections being loadable into and / or executable in a system to make the system 200 execute the steps for performing the said purpose.

[0032] Generally, as used herein, the term "processing unit" refers to a computational element that is operable to respond to and processes instructions that drive the system 200. Optionally, the processing unit includes, but is not limited to, a microprocessor, a microcontroller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing circuit. Furthermore, the term "processing unit" may refer to one or more individual processors, processing devices and various elements associated with a processing device that may be shared by other processing devices. Additionally, the one or more individual processors, processing devices and elements are arranged in various architectures for responding to and processing the instructions that drive the system 200.

[0033] Herein, the memory unit 206 may be volatile memory and / or nonvolatile memory. The memory unit 206 may be coupled for communication with the processing unit 204. The processing unit 204 may execute instructions and / or code stored in the memory unit 206. A variety of computer-readable storage media may be stored in and accessed from the memory unit 206. The memory unit 206 may include any suitable elements for storing data and machine- readable instructions, such as read only memory, random access memory, erasable programmable read only memory, electrically erasable programmable read only memory, a hard drive, a removable media drive for handling compact disks, digital video disks, diskettes, magnetic tape cartridges, memory cards, and the like.

[0034] In particular, the processing unit 204 has connectivity to the bus 202 to execute instructions and process information stored in the memory unit 206. The processing unit 204 may include one or more processing cores with each core configured to perform independently. A multi-core processor enables multiprocessing within a single physical package. Examples of a multi-core processor include two, four, eight, or greater numbers of processing cores. Alternatively, or in addition, the processing unit 204 may include one or more microprocessors configured in tandem via the bus 202 to enable independent execution of instructions, pipelining, and multithreading. The processing unit 204 may also be accompanied with one or more specialized components to perform certain processing functions and tasks such as one or more digital signal processors (DSP) , and / or one or more application-specific integrated circuits (ASIC) . Other specialized components to aid in performing the inventive functions described herein include one or more field programmable gate arrays (FPGA) (not shown) , one or more controllers (not shown) , or one or more other special-purpose computer chips.

[0035] The system 200 may further include an interface 208, such as a communication interface (with the said terms being interchangeably used) which may enable the system 200 to communicate with other systems for receiving and transmitting information. The communication interface 208 may include a medium (e.g., a communication channel ) through which the system 200 communicates with other system . Examples of the communication interface 208 may include, but are not limited to, a communication channel in a computer cluster, a Local Area Communication channel (LAN) , a cellular communication channel , a wireles s sensor communication channel (WSN) , a cloud communication channel , a Metropolitan Area Communication channel (MAN) , and / or the Internet . Optionally, the communication interface 208 may include one or more of a wired connection, a wireles s network, cellular networks such as 2G, 3G, 4G, 5G mobile networks , and a Zigbee connection .

[0036] The system 200 also includes a database 210 . As used herein, the database 210 is an organized collection of structured data, typically stored in a computer system and des igned to be easily acces sed, managed, and updated . The database 210 may be in form of a central repository of information that may be queried, analysed, and proces sed to support various applications and busines s proces ses . In the system 200 , the database 210 provides mechanisms for storing, retrieving, updating, and deleting data, and typically includes features such as data validation, security, backup and recovery, and data modelling .

[0037] The system 200 further includes an input device 212 and an output device 214 . The input device 212 may take various forms depending on the specific application of the system 200 . In an example, the input device 212 may include one or more of a keyboard, a mouse , a touchscreen display, a microphone , a camera, or any other hardware component that enables the user to interact with the system 200 . Further, the output device 214 may be in the form of a display, a printer, a communication channel, or the like, without any limitations .

[0038] In the present system 200, the processing unit 204 and accompanying components have connectivity to the memory unit 206 via the bus 202. The memory unit 206 includes both dynamic memory (e.g. , RAM, magnetic disk, writable optical disk, etc. ) and static memory (e.g., ROM, CD-ROM, etc. ) for storing executable instructions that when executed perform the method steps described herein for data routing in a distributed control system (DCS) . In particular, the memory unit 206 includes a data routing module 216 to perform steps for the said purpose.

[0039] FIG 3 is a schematic representation of an architecture for a distributed control system (DCS, as represented by reference numeral 300) , in accordance with one or more embodiments of the present invention. As illustrated, the DCS 300 includes a plurality of virtual connectors (VCs) 310. Herein, each of the plurality of virtual connectors 310 is designated by a reference character such as VC1, VC2, up to VCN, where N represents the total number of virtual connectors within the DCS 300. These virtual connectors 310 are configured to establish interfaces between a set of communication channels 312 (represented by Cl through CN) , and instrument signals 314 (labelled SI, S2, up to S16) . Each communication channel 312 (Cl-CN) correlates to a respective virtual connector 310 (VC1-VCN) , ensuring that there is a structured and systematic pathway for data exchange within the DCS 300. Further, each instrument signal 314 (S1-S16) represents a data point or input from field devices 316, which may include sensors or actuators deployed throughout the industrial environment . These instrument signals 314 are the data source for the DCS 300 , requiring accurate and reliable routing to ensure the efficacy of the control proces ses .

[0040] In the depicted embodiment , the plurality of virtual connectors 310 and the set of communication channels 312 are provided in a cabinet 318 (marshalling cabinet ) . The cabinet 318 may be in the form of an enclosure and serves as a mounting framework for the virtual connectors 310 and the communication channels 312 . In some examples , the DCS 300 may be provided with a collector 320 as sociated with the plurality of virtual connectors 310 . The collector 320 may be in the form of an intermediary node that consolidates data from the various virtual connectors 310 within the DCS 300 . The collector 320 acts as a centrali zed point of data aggregation, facilitating the transmis sion of data in the DCS 300 .

[0041] The DCS 300 of the present invention further includes a data acquisition module 322 . The data acquis ition module 322 i s configured for monitoring a suite of operational parameters . These parameters encompas s details regarding the availability of communication channels 312 within the DCS 300 , the current status of these communication channel s 312 , the designated priorities for the instrument signals 314 , particular interest s regarding specific communication channels 312 in relation to instrument signals 314 , and the loading percentages of the communication channels 312 . The DCS 300 further includes a data routing module 324 configured for orchestrating the flow of information within the DCS 300 , specifically information flow related to interfacing between various communication channels 312 and the instrument signals 314 . More specifically, the data routing module 324 i s configured to determine signal-to-channel as signments based on the gathered operational parameters . These as signments specify which of the multiple virtual connectors 310 should interface with the corresponding communication channels 312 and the instrument signals 314 . Once these determinations are made, the data routing module 324 proceeds to communicate the s ignal-to-channel as signments both to the plurality of virtual connectors 310 and a command centre 326 . The execution of these signal-to-channel as signments enables the dynamic adjustment of the s ignal-to- channel connections within the DCS 300 . This execution i s a coordinated effort , involving the virtual connectors 310 and the command centre 326 , each performing their designated roles to ensure the DCS 300 operates seamles sly and efficiently .

[0042] In the DCS 300 , the virtual connectors 310 and the command centre 326 work collectively to automatically reconfigure connections between the communication channels 312 and the instrument s ignal s 314 , based on the s ignal-to-channel as s ignments determined by the data routing module 324 . The data acquisition module 322 may further facilitate the transmi s sion of acknowledgments from the virtual connectors 310 back to the data routing module 324 , thus confirming the succes s ful reconfiguration of the connections . Furthermore, the data routing module 324 configures the command centre 326 to update the details pertaining to the reconfiguration of connections , ensuring that the records accurately reflect the current operational state . This configuration enables the DCS 300 for sel f-regulation and to maintain an updated, reliable control environment . More specifically, in the DCS 300, the virtual connectors 310 play a role in ensuring seamless communication and efficient data transfer within the DCS 300. Specifically, the virtual connectors 310 serves as slave devices, strategically positioned in the cabinet 318 of the DCS 300, with fixed terminations on both sides, i.e. , the field devices 316 or the instrument signals 314 on one side, and the communication channels 312 on other side to facilitate data exchange. The core principle behind the virtual connector 310 is its ability to take instructions from the data routing module 324 for internal routing. By adhering to the guidance of the data routing module 324, the virtual connector 310 can efficiently direct data traffic, ensuring seamless communication between different components of the DCS 300.

[0043] The data routing module 324, which may be residing in the private cloud space, is the master device responsible for decision-making and data management. With connections to both the virtual connectors 310 and the command centre 326, the data routing module 324 plays a role in determining the optimal connections between the communication channels 312 and the instrument signals 314. The decisions of the data routing module 324 are communicated to all of the virtual connectors 310, which, in turn, create internal routing paths to link the communication channels 312 and the instrument signals 314 precisely as directed. The data routing module 324 determines the optimal connections between the communication channels 312 and the instrument signals 314, thereby orchestrating the efficient flow of information. When the data routing module 324 makes decis ions regarding connections , these instructions are promptly transmitted to all the virtual connectors 310 . Consequently, the virtual connectors 310 establi sh the internal routing neces sary to link the communication channels 312 and the instrument signals 314 as per directives from the data routing module 324 . Simultaneously, the information related to these connections ( channel as signment details ) is updated in the command centre 326 . This synchroni zation ensures that the values of the instrument signals 314 are visible in Human-Machine Interface (HMI ) of the command centre 326 , allowing operators to monitor and control the DCS 300 with accuracy and reliability .

[0044] The collector 320 collects information from various VCs 310 within a single rack or the cabinet 318 . This collected data is then pas sed on to the data routing module 324 , enabling bidirectional communication . Similarly, the deci sions of the data routing module 324 are relayed back to the VCs 310 via the collector 320 , which then establish internal routing connections to link the communication channels 312 and the instrument signals 314 . Thi s bidirectional flow promotes real-time data updates and enhances the overall ef ficiency of the DCS 300 .

[0045] In the DCS 300 , the initial as signment of the communication channels 312 to the instrument signal s 314 during the commis s ioning stage sets the foundation for a seamles s operational flow . This proces s includes a series of coordinated steps between the command centre 326 , the data routing module 324 , the collector 320 , and the plurality of virtual connectors 310 . This synchronized interaction facilitates informed decision-making and timely updates based on critical engineering parameters. The process involves the command centre 326 gathering essential information related to the communication channels 312, which includes details such as the loading percentage indicative of spare communication channels 312, the status of communication channels 312, the assignment of instrument signals 314 to the communication channels 312, and the total number of communication channels 312 per card, reflecting channel density. The command centre 326 transmits this information to the data routing module 324. The data routing module 324 evaluates the information to make informed routing decisions for the DCS 300. Further, the data routing module 324 communicates these decisions to the collector 320, which acts as a gateway, passing on instructions from the data routing module 324 to the virtual connectors 310. The virtual connectors 310, with their inherent responsiveness, execute the instructions provided by the data routing module 324 via the collector 320. Upon successful completion of these tasks, the virtual connectors 310 issue an acknowledgment back to the collector 320, confirming the execution of the instructions from the data routing module 324. Further, the process involves the data routing module 324 receiving feedback from the collector 320 and, based on the actions of the virtual connectors 310, sending specific addressing information back to the command centre 326 for further system updates and coordination. The final output, which includes updated values and configurations, is reflected in a User Interface (UI) of the command centre 326. This UI presents an accurate visual representation of the current state of the DCS 300 for reference of the operators, as defined by the signal-to-channel connections established by the data routing module 324. Further, in the DCS 300 , optimizing allocation of new communication channel 312 during the runtime failure of a communication channel constitutes a structured procedure used for maintaining uninterrupted system performance . This ensures that the virtual connectors 310 , the collector 320 , the data routing module 324 , and the command centre 326 work together to manage and allocate channels efficiently, especially in the event of a failure . Such proces s begins with the command centre 326 identifying a faulty communication channel 312 within a card of the cabinet 318 . In such case, the command centre 326 generates and sends a detailed report to the data routing module 324 outlining the is sues as sociated with the specific channel number on the identified card . Subsequently, the data routing module 324 conduct s an analysis of the feedback received from the command centre 326 , utiliz ing multiple inputs to determine a decis ion on the reallocation of communication channels 312 to maintain system integrity . The data routing module 324 , then, communicates instructions to the collector 320 , specifying which new spare communication channels 312 should be as signed to the af fected instrument s ignal s 314 . The collector 320 act s upon the instructions from the data routing module 324 and transmits this information to the relevant virtual connectors 310 tasked with managing the communication channels 312 . The virtual connectors 310 acknowledging the receipt of instructions from the collector 320 , confirms their readines s to implement the neces sary adjustments for allocations to the communication channel 312 . Once the virtual connectors 310 have signalled their acknowledgment , the collector 320 relays this confirmation back to the data routing module 324 . Thi s indicates that the virtual connectors 310 have succes s fully routed the instrument signals 314 to the available spare communication channels 312 as directed by the data routing module 324 . Further, the proces s involves the data routing module 324 sending updated addres sing detail s back to the command centre 326 . This includes specific configurations and the locations of the newly as signed communication channels 312 . The command centre 326 integrates the addres sing information from the data routing module 324 , updating the engineering parameters to reflect the new configuration . The proces s i s concluded as the updated engineering values , signifying the newly established connections for the communication channel 312 , are accurately depicted within the UI , ensuring that the operators have the latest information for effective system monitoring and control .

[0046] Thereby, the DCS 300 of the present invention, in the pursuit of optimizing data flow, streamlines signal to channel as signment and enhances connectivity between field devices and card channels . The DCS 300 of the present invention introduces the virtual connectors 310 as a middle layer, the collector 320 as a gateway and the data routing module 324 as a decis ion maker . It may be understood that ensuring accurate channel as signment is critical for operations of the DCS 300 . Any mismatch in channel addres sing could lead to erroneous actions , potentially disrupting the entire proces s . As such, during the engineering phase, attention i s paid to avoid manual addres sing errors . The DCS 300 of the present invention prioritizes preci sion and accuracy to maintain smooth operations and prevent any unwanted disruptions .

[0047] The DCS 300 is designed to implement the method 100 of data routing as per the present invention . The data routing module 324 , with in the DCS 300 , i s implemented for monitoring operational parameters from the command centre 326 , determining s ignal-to-channel as signments , communicating these as s ignments to the virtual connectors 310 and the command centre 326 , and executing the as signments to adaptively adjust s ignal-to-channel connections within the DCS 300 . The method 100 and the system 200 of the present invention i s implemented within the DCS 300 . Referring to FIGS 1-3 in combination, various steps of the method 100 (as described hereinafter) , which may be executed in the system 200 , or specifically in the proces sing unit 204 of the system 200 , for data routing in the DCS 300 , are described . It may be appreciated that although the method 100 i s illustrated and des cribed as a sequence of steps , it may be contemplated that various embodiment s of the method 100 may be performed in any order or dif ferent combinations , and need not include all of the illustrated steps .

[0048] At step 110 , the method 100 includes implementing the plurality of virtual connectors (VCs ) 310 , each VC 310 configured to interface between the one or more communication channels 312 of the DCS 300 and the one or more instrument signals 314 . As di scus sed, the DCS 300 includes the implementation of the plurality of virtual connectors 310 . Each virtual connector 310 i s configured to serve as an interface between the one or more communication channel s 312 of the DCS 300 and the one or more instrument signals 314 . The virtual connectors 310 are implemented in the architecture of the DCS 300 , establishing a flexible communication framework that is capable of managing the complex data flow within the DCS 300 . The virtual connectors 310 are specifically designed to adapt to the varying requirements of the DCS 300 , ensuring that each communication channel 312 is properly aligned with the appropriate instrument signals 314 . This configuration facilitates the exchange of data between the field devices (or sensors ) 316 and the DCS 300 , enabling real-time monitoring and control of the industrial proces s .

[0049] At step 120 , the method 100 includes monitoring, by the data acquisition module 322 from the command centre 326 , operational parameters for the DCS 300 , the operational parameters comprising information about one or more of available communication channel s 312 of the DCS 300 , current statuses of the communication channel s 312 of the DCS 300 , priorities for the instrument signals 314 , specific interests for communication channel s 312 vis-a-vis the instrument signals 314 , and loading percentages of the communication channel s 312 of the DCS 300 . That is , within the DCS 300 , the data acquisition module 322 as sociated with the command centre 326 is configured for the continual monitoring of operational parameters for the DCS 300 . Thi s continuous surveillance includes a comprehensive range of operational parameters that are important for effective performance of the DCS 300 .

[0050] The operational parameters monitored by the data acquisition module 322 include the availability of communication channels 312 within the DCS 300 , which are critical for ensuring there are no bottlenecks in data flow . Furthermore , the data acquisition module 322 systematically observes the current statuses of the communication channels 312 of the DCS 300 , which is used in recognizing and responding to faults or degradations in channel performance . Additionally, the data acquisition module 322 evaluates the priorities as signed to the instrument signal s 314 . This prioritization i s a key factor that influences how the DCS 300 allocates resources and manages the data routing to ensure that critical processes receive the necessary attention and bandwidth. The data acquisition module 322 also examines specific interests for communication channels 312 vis-a-vis the instrument signals 314. This analysis aids in the tailoring of the data flow within the DCS 300, aligning specific instrument signals 314 with designated communication channels 312 for optimized performance. Lastly, the loading percentages of the communication channels 312 are continuously assessed by the data acquisition module 322. Understanding the loading percentages allows the DCS 300 to balance the data throughput, preventing any single communication channel 312 from becoming a point of failure due to overloading, and thus ensuring an even distribution of data processing tasks.

[0051] At step 130, the method 100 includes determining, by the data routing module 324, signal-to-channel assignments based on the operational parameters for the DCS 300, with each signal-to- channel assignment designating at least one of the plurality of VCs 310 to interface between specific communication channel (s) 312 of the DCS 300 and specific instrument signal (s) 314. As discussed, within the framework of the DCS 300, the data routing module 324 undertakes the role of determining signal-to-channel assignments. These assignments are derived based on a comprehensive analysis of the operational parameters monitored within the DCS 300. The process ensures that each signal-to-channel assignment accurately designates at least one from the plurality of virtual connectors 310 to establish an interface between specific communication channels 312 of the DCS 300 and corresponding specific instrument signals 314. The data routing module 324 operates by evaluating parameters such as the availability and status of communication channel s 312 , along with the priority levels and loading percentages as signed to each instrument signal 314 . By integrating this data, the data routing module 324 may as sign the appropriate virtual connectors 310 to facilitate the required connectivity . This connectivity i s dynamically tailored to reflect the current operating conditions and requirements of the DCS 300 , ensuring that the data flow is optimized for efficiency and reliability . The as signment proces s carried out by the data routing module 324 provides adaptability to the DCS 300 to respond swi ftly to changing conditions , such as channel overloads or signal priority shifts , thereby ensuring operational integrity of the industrial proces ses controlled by the DCS 300 .

[0052] In an embodiment , the method 100 comprises proces sing, by the data routing module 324 , the information about the current statuses of the communication channels 312 of the DCS 300 to determine presence of one or more faulty communication channels of the DCS 300 . For this purpose , the data routing module 324 within the DCS 300 is responsible for proces sing information regarding the current statuses of the communication channels 312 . This proces s involves a detailed examination of functionality of each communication channel 312 to determine the presence of faults or inefficiencies within the communication channel s 312 of the DCS 300 . The identification of any such faults by the data routing module 324 ensure the reliability and continuity of operations of the DCS 300 . In such case, the method 100 comprises adjusting the s ignal- to-channel connections to as sign one or more spare channel s from the available communication channels 312 of the DCS 300 for the instrument signals 314 corresponding to the one or more faulty communication channels of the DCS 300. That is, upon the identification of one or more faulty communication channels 312, the data routing module 324 initiates a procedure to adjust the signal-to-channel connections. This adjustment involves realignment of the data pathways within the DCS 300, ensuring that the instrument signals 314, which were previously associated with the now-identified faulty communication channels 312, are reassigned. The reassignment leverages one or more spare channels from the pool of available communication channels 312, which have been predetermined and set aside specifically for such contingencies. This adjustment ensures that the instrument signals 314, corresponding to the detected faulty communication channels 312, continue to be transmitted effectively within the DCS 300, thus mitigating any potential disruption in the operations of the DCS 300.

[0053] In some embodiments, the method 100 comprises processing, by the data routing module 324, the information about the priorities for the instrument signals 314 to determine high-priority instrument signals. For this purpose, the data routing module 324 within the DCS 300 processes information related to the priorities of the instrument signals 314 as may be pre-defined or provided by the command centre 326. The data routing module 324 may evaluate this information to determine which of the instrument signals 314 are deemed high-priority, a classification used for ensuring the uninterrupted operation of essential processes within the DCS 300. The method 100 further includes prioritizing the assignment of the one or more spare channels from the available communication channels 312 of the DCS 300 to the high-priority instrument signals from the instrument signals 314 corresponding to the one or more faulty communication channels of the DCS 300 . That is , once the high-priority instrument signals 314 have been identified, the data routing module 324 then engages in a selective proces s to prioritize the allocation of spare communication channels 312 . This prioriti zation i s es sential , particularly when one or more communication channel s 312 within the DCS 300 are found to be faulty . The data routing module 324 ensures that these high- priority instrument signals 314 are given precedence in the as signment of spare channels , thereby reallocating resources within the DCS 300 to uphold the most critical aspects of functionality of the DCS 300 . Thi s targeted prioritization proces s managed by the data routing module 324 allows the DCS 300 to maintain operational resilience and ef ficiency, even in case of component failures . By ensuring that high-priority instrument signals 314 receive immediate attention and neces sary resources , the DCS 300 enhances its capability to manage and mitigate the impacts of channel faults , thereby sustaining the reliability of the controlled industrial proces ses .

[0054] In an embodiment , the method 100 includes proces s ing, by the data routing module 324 , the information about the loading percentages of the communication channels 312 of the DCS 300 to determine presence of one or more overloaded communication channels of the DCS 300 . That is , the data routing module 324 within the DCS 300 proces ses the information regarding the loading percentages of the communication channels 312 . The proces s ing of loading percentages is a measure of the volume of data traffic that each communication channel 312 is handling, relative to its maximum capacity . This operation detects the presence of one or more overloaded communication channels 312 within the DCS 300 . The method 100 further comprises adjusting the signal-to-channel connections to as sign one or more spare channel s from the available communication channels 312 of the DCS 300 for the instrument signals 314 corresponding to the one or more overloaded communication channel s of the DCS 300 . That is , once the data routing module 324 identifies any communication channels 312 that are operating beyond their optimal load capacity, it proceeds to implement adjustments in the signal-to-channel connections . This adjustment is a recalibration proces s where the data routing module 324 as signs one or more spare channels from the pool of available communication channel s 312 within the DCS 300 . These spare channels are allocated to accommodate the instrument signals 314 that were initially routed through the overloaded communication channel s 312 . Thi s proactive adjustment by the data routing module 324 helps against potential data transmi s sion delays or los ses that could arise from channel overloading . Such adjustment ensures that instrument signals 314 are rerouted to spare channels that can handle the data flow without compromi se . By executing these adjustments , the DCS 300 maintains optimal data traffic di stribution acros s its network .

[0055] In an embodiment , the method 100 includes proces s ing, by the data routing module 324 , the information about the speci fic interests for communication channels 312 vis-a-vi s the instrument signals 314 to determine particular communication channel ( s ) of the DCS 300 for specific instrument signal ( s ) . Herein, the data routing module 324 within the DCS 300 proces ses information regarding specific interests for communication channels 312 in relation to the instrument signals 314 , as may be predefined or received from the command centre 326. This process involves analysing the operational needs and requirements to identify which particular communication channels 312 should be dedicated to specific instrument signals 314. The objective is to determine the optimal routing paths that align with the strategic interests and priorities of the DCS 300, ensuring that certain critical instrument signals 314 are provided the appropriate communication channels 312 for their transmission. The method 100 further includes adjusting the signal-to-channel connections to bind the particular communication channel (s) of the DCS 300 for the specific instrument signal (s) . Upon identifying the particular communication channels 312 suited for the designated specific instrument signals 314, the data routing module 324 initiates adjustments in the signal-to-channel connections. This adjustment involves effectively binding the selected communication channels 312 to the identified specific instrument signals 314. The purpose of this binding is to ensure a dedicated pathway for signal transmission that meets the unique demands of specific operational scenarios within the DCS 300. By carrying out these adjustments, the data routing module 324 facilitates a tailored communication infrastructure within the DCS 300. This targeted approach allows for the prioritization of certain instrument signals 314, ensuring that they have uninterrupted access to communication channels 312, which are most suited to their function.

[0056] At step 140, the method 100 includes communicating, by the data routing module 324, the signal-to-channel assignments to the plurality of VCs 310 and the command centre 326. That is, the data routing module 324, having analyzed the operational parameters and determined the optimal signal-to-channel assignments, proceeds to communicate this information. As discussed, the signal-to-channel assignments include specific directives on how each virtual connector 310 should interface the instrument signals 314 with the appropriate communication channels 312 of the DCS 300. This could entail rerouting signals, allocating spare channels for overloaded or faulty channels, or prioritizing certain signals over others based on their importance to the process being controlled. This communication ensures all components within the DCS 300 are synchronized with the latest configuration settings and operational directives.

[0057] In the present configuration, the communication to the virtual connectors 310 is carried out through a predefined protocol that ensures the secure and accurate transmission of assignment data. Each virtual connector 310 receives instructions relevant to its operation, enabling it to adjust its configuration dynamically to align with the new assignments. Simultaneously, the command centre 326 is updated with information about the new signal-to-channel assignments. This ensures that the command centre 326 maintains a holistic view of configuration, facilitating effective monitoring and control of the DCS 300. The command centre 326, equipped with this updated information, can provide operators with real-time insights into status and assist in decision-making processes, related to the DCS 300.

[0058] At step 150, the method 100 includes executing, by the plurality of VCs 310 and the command centre 326, the signal-to-channel assignments to dynamically adjust signal-to-channel connections within the DCS 300. Such execution of the signal-to-channel assignments within the DCS 300 is a coordinated effort involving the plurality of virtual connectors 310 and the command centre 326 . Herein, upon receiving the signal-to-channel ass ignments from the data routing module 324 , each virtual connector 310 within the plurality initiates the proces s of dynamically adjusting the signal-to-channel connections . Thi s involves reconfiguring the interfaces between the specific communication channels 312 of the DCS 300 and the designated instrument signals 314 . The virtual connectors 310 , equipped with the capability to modify connections based on software commands , efficiently reroute signals to align with the new as s ignments . Simultaneously, the command centre 326 facilitates the execution proces s by ensuring that the overall system reflects the changes defined in the signal-to-channel as signments . The command centre 326 may also be involved in executing broader system-level adjustment s , including updating system-wide configurations , providing feedback to the data routing module 324 , or enabling operator interventions if neces sary .

[0059] In an embodiment , the step of executing, by the plurality of VCs 310 and the command centre 326 , the signal-to-channel as signment s to dynamically adjust signal-to-channel connections within the DCS 300 comprises automatically reconfiguring the connect ion ( s ) between the one or more communication channels 312 of the DCS 300 and the one or more instrument signals 314 via the plurality of VCs 310 based on the signal-to-channel as signment s . The automatic reconfiguration proces s is carried out by the virtual connectors 310 , each of which is configured to modify the connections between one or more communication channels 312 of the DCS 300 and one or more instrument signals 314 . This reconfiguration is defined by the signal-to-channel as signments previously determined by the data routing module 324 . The as s ignments provide an outline for how the virtual connectors 310 should reroute the instrument signals 314 , ensuring that they are interfaced with the optimal communication channels 312 for effective data transmis sion within the DCS 300 . Thi s ability to dynamically adjust connections promotes enhanced reliability and adaptability in industrial proces s control .

[0060] In some embodiment s , the method 100 further comprises sending an acknowledgement by the plurality of VCs 310 to the data routing module 324 confirming the reconfiguration of the connection ( s ) between the one or more communication channels 312 of the DCS 300 and the one or more instrument s ignals 314 . That is , following the execution of the s ignal-to-channel as signments within the DCS 300 , the plurality of virtual connectors 310 proceed to send an acknowledgement to the data routing module 324 which confirms that the reconfiguration of the connections between the one or more communication channels 312 and the one or more instrument s ignal s 314 has been succes s fully completed . The transmis sion of thi s acknowledgement by the virtual connectors 310 to the data routing module 324 serves as a feedback mechanism, ensuring that the automatic reconfigurations have been enacted according to the determined as signment s . This feedback loop between the virtual connectors 310 and the data routing module 324 maintains the operational integrity of the DCS 300 . Specifically, such acknowledgement provides the data routing module 324 with realtime status updates , enabling it to maintain an accurate and current overview of network configuration of the DCS 300 .

[0061] In some embodiments , the method 100 further comprises configuring, by the data routing module 324 , the command centre 326 to update details about the reconfiguration of the connection ( s ) between the one or more communication channels 312 of the DCS 300 and the one or more instrument signals 314 via the plurality of VCs 310 . That is , subsequent to receiving the acknowledgement from the plurality of virtual connectors 310 , the data routing module 324 configures the command centre 326 . This configuration involves updating the command centre 326 with detailed information about the recent reconfigurations of the connections between the one or more communication channel s 312 of the DCS 300 and the one or more instrument signal s 314 , facilitated by the virtual connectors 310 . These details include specifics on which instrument signals 314 are now routed through which communication channels 312 , following the dynamic adjustments by the virtual connectors 310 based on the signal-to-channel as signments . Thi s step ensures that the command centre 326 can provide accurate real-time data to operators and other system components , enhancing the overall transparency and effectivenes s of the DCS 300 .

[0062] Referring now to FIG 4 , illustrated is a schematic representation of a workflow ( as represented by reference numeral 400 ) for data routing in the DCS 300 , in accordance with one or more embodiment s of the present invention . The workflow 400 depicts a systematic flow of information and commands between the virtual connectors 310 , the data routing module 324 and the command centre 326 , as facilitated by the data acqui sition module 322 . the interplay and collaborative functioning of the DCS 300 component s in executing data routing procedures . The workflow 400 , thereby, captures the interplay and collaborative functioning of the DCS 300 component s in executing data routing procedures . In the workflow 400 , the command centre 326 serves as the origination point for operational parameters data . The command centre 326 sends a comprehens ive set of operational parameters to the data routing module 324 , which includes the priority of instrument signals 314 , the loading percentage of communication channels 312 , a detailed signal li st , the total channel count for the communication channels 312 indicative of channel density, and the status of each communication channel 312 . Thi s data about the operational parameters is used by the data routing module 324 to make informed decisions regarding signal-to-channel as signment s within the DCS 300 .

[0063] The data routing module 324 , after proces sing the incoming information, generates instructions that provide an optimized routing strategy for the DCS 300 . These instructions are based on the need to ensure uninterrupted signal transmis sion, especially in s cenarios where certain communication channels 312 are identified as compromised or faulty . The data routing module 324 commands the rerouting of affected instrument s ignals 314 to available spare channels within the DCS 300 , using the virtual connectors 310 for implementation .

[0064] Further, upon succes s ful receipt and execution of the instructions by the virtual connectors 310 , an acknowledgement is communicated back to the data routing module 324 . This acknowledgement confirms that the instructions have been understood and acted upon, completing the loop of communication and ensuring the data routing module 324 has an updated status of configuration of the DCS 300 . Simultaneously, the data routing module 324 interfaces with the command centre 326 to facilitate updates or changes to the addres s information based on the new routing configuration. This update ensures that the process value in HMI and logics is available without manually changing the channel allocation, and that the command centre 326 maintains accurate information of the signal paths and channel statuses within the DCS 300.

[0065] Referring to FIG 5, illustrated is an exemplary configuration for various use cases (to be discussed in the proceeding paragraphs) within the DCS 300. The exemplary configuration depicts an arrangement of three Analog Input (Al) cards. The Al cards are denoted as CAI through CA16, CB1 through CB16, and CC1 through CC16, which represent the communication channels 312 of the DCS 300 mounted within the automation racks. These communication channels 312 are connected to the field devices 316 through the virtual connectors 310, with the virtual connectors 310 being interlinked to facilitate communication within the DCS 300. Instrument signals 314, referred to as Sigi, Sig2, Sig3, and so on, from the field devices 316 are terminated at the virtual connectors 310. Conversely, the communication channels 312, such as CAI, CA2, through CA16, CB1, CB2, through CB16, CC1, CC2, through CC16, are terminated at the other end of the virtual connectors 310. In this configuration, each Al card is equipped with 16 channels, adhering to a project-specific requirement to maintain a 10% spare channels, resulting in 14 channels (CA1-CA14, CB1-CB14, CC1-CC14) actively connected to instrument signals from the field and 2 channels reserved as spare (CA15-CA16, CB15-CB16, CC15-CC16) in each Al card.

[0066] Upon system activation, the virtual connectors 310 establish logical connections for the instrument signals 314 such as Sigi, Sig2, directing them to the appropriate communication channels 312 based on the assigned priorities and any necessary redundancy requirements while leaving spare channels unassigned. The data routing module 324 is responsible for these logical assignments. Once these channel-to-signal assignments are determined, the information is transmitted to the command centre 326, ensuring that the hardware termination details are synchronized. This maintains accurate information of the physical connections within the DCS 300.

[0067] FIG 6 presents a first use-case (Case-1) in which an issue is identified with communication channel CA3 of Al card-1, which is designated as a faulty channel and was logically connected to instrument signal Sig7. When the data routing module 324 and subsequently the command centre 326 receive notification of the fault in communication channel CA3, this information is promptly communicated to the virtual connectors 310. The data routing module 324, upon receipt of this information, makes a decision regarding the reassignment of the instrument signal Sig7 that was previously associated with the now-faulty communication channel CA3. In this case, the data routing module 324 determines that instrument signal Sig7 should be reassigned to another healthy and available spare communication channel within the pool, using the virtual connectors 310. Due to availability of spares across the 3 Al cards, which in total provide 6 spare communication channels, the virtual connectors 310 may be implemented to select CA15 of Al card-1 as the new channel for instrument signal Sig7. This decision takes into account the health and availability of the spare communication channels across all Al cards to ensure continuous operation without disruption to the signal transmission within the DCS 300. This reassignment is executed by the virtual connectors 310, which then communicate the new configuration back to the data routing module 324 and the command centre 326, updating the system database to reflect the change.

[0068] FIG 7 presents a second use-case (Case-2) in which multiple communication channels fail on a single Al card. Specifically, communication channels CB5, CB6, and CB7 of Al card-2 have encountered faults, and only two spare communication channels are available on that card. Traditionally, to address such a failure, a physical intervention would be required. If the field wire within the cabinet was of sufficient length, it might be possible to manually rewire the connections to the next available spare channels on a different Al card. However, if the field wire lacked the necessary length or if the next Al card was located in a different cabinet, significant challenges would arise. These could include the need to lay a new 12-pair cable from the field to the next cabinet or even to replace the entire faulty Al card-2.

[0069] In contrast, the solution provided by the DCS 300 with the virtual connectors 310 eliminates the need for such cumbersome physical interventions. When communication channels CB5, CB6, and CB7 of Al card-2 fail, the virtual connectors 310 can immediately reassign the impacted instrument signals to any available spare communication channels across the entirety of the DCS 300, regardless of their physical location within the cabinets. For instance, instrument signals Sig24, Sig23, and Sig22, which were initially logically connected to the faulty channels on Al card- 2, are reassigned by the virtual connectors 310 to the 15th communication channels CA15, CB15, and CC15 of Al card-1, Al card- 2, and Al card-3, respectively. This reassignment is performed logically and does not require any physical rewiring or new cable laying, indicating the efficiency of the virtual connectors 310 of the DCS 300. Furthermore, these new signal-to-channel assignments are automatically updated in the command centre 326, ensuring that operational database remains synchronized with the actual state of the field connections, maintaining the integrity and continuity of the DCS 300 despite the occurrence of multiple communication channel failures.

[0070] FIG 8 presents a third use-case (Case-3) which outlines the procedure for prioritized channel assignment in case of channel failures, emphasizing the precedence of high-priority instrument signals over low-priority ones. In this scenario, two communication channels are impacted, including one that carries a low-priority instrument signal Sig28, and another carrying a high- priority instrument signal Sig39. The data routing module 324, in this case, ensure that Sig39 is reassigned to an available spare communication channel, specifically CC15 of Al card-3, which is designated to handle such high-priority tasks. This reallocation allows the crucial processes linked to Sig39 to continue without interruption, maintaining critical operations. Subsequently, the low-priority instrument signal Sig28 may be reassigned to another available spare communication channel, such as CB15 of Al card-2. This secondary adjustment is made after ensuring that the high- priority signals have been accommodated, thereby efficiently utilizing the spare resources within the DCS 300. It may be understood that each instrument signal is assigned a priority level (high or low) at the command centre 326, which is then utilized by the data routing module 324 during channel as signment in instances where a communication channel becomes faulty .

[0071] FIG 9 present s a fourth use-case ( Case-4 ) which provides a scenario where spare communication channels are strategically reserved for high-priority instrument signals . In thi s case, all four spare communication channels from Al card 1 and Al card 2 are already utilized, leaving only two spare communication channels from Al Card-3 available . Now, communication channels CC4 and CC5 of Al Card-3 have become faulty, af fecting instrument s ignal s Sig39 and Sig38 , both of which are deemed low priority . Given the strategy, these low-priority instrument signals Sig39 and Sig38 will not be reas signed to the last remaining spares , CC15 and CC16 , due to their priority status . The DCS 300 , particularly the virtual connectors 310 , will hold these spare communication channel s in reserve, ensuring that they are available for any future high- priority instrument signals that may require immediate attention due to channel faults . This approach ensures that at least two spare communication channels remain on standby within the DCS 300 , specifically for high-priority instrument signals , to maintain critical operations in the DCS 300 .

[0072] The method 100 and the system 200 of the present invention implement "virtual termination" technique for s ignal-to-channel as signments to manage the DCS 300 . The present invention provides intelligent automation, where the data routing module 324 performs automatic channel as signments by considering an array of critical parameters . This includes as ses sing loading percentages , the status of communication channels 312 from the card, the total number of communication channels 312 per card, a li st of instrument signals 314 , and the priority of these signals . The present invention offers various configurations to cater to dif ferent needs and scenarios . The four di fferent ways of channel as signment (within card, in other cards , reserved for critical signals , and based on signal priority ) provide flexibility and adaptability to diverse use cases . All VCs are interconnected and pas sing information to the data routing module 324 , which can support multiple VCs available in the card, enhancing coordination and centralized control .

[0073] The strategic placement of the virtual connectors 310 at the cabinet 318 ensures proper physical connections between the field devices 316 and the communication channels 312 of the card . The internal routing based on decisions adds an extra layer of intelligence and optimization . The data routing module 324 handles channel as s ignment through VCs 310 not only during the initial as signment but also during the faulty stage of the instrument signals 314 . This dynamic and adaptive approach ensures uninterrupted functionality even in the presence of faults . Further, the capability of the virtual connector 310 to perform connection distribution virtually removes the need to maintain or record termination details of modules manually . Thi s simplifies and reduces administrative burdens for maintaining the DCS 300 . Thus , the present method 100 leverages the virtual connectors 310 to intelligently as s ign channel s based on critical aspect s and provide multiple configurations , dynamic as signment , and elimination of manual termination detail s maintenance . Thi s comprehensive and intelligent approach enhances efficiency, reliability, and scalability in channel management for the control system . While the present invention has been des cribed in detail with reference to certain embodiments , it should be appreciated that the present invention i s not limited to those embodiment s . In view of the present invention, many modifications and variations may be present themselves , to those skilled in the art without departing from the scope of the various embodiments of the present invention, as described herein . The scope of the present invention is , therefore , indicated by the following claims rather than by the foregoing description . All changes , modifications , and variations coming within the meaning and range of equivalency of the claims are to be cons idered within their scope .

Claims

PATENT CLAIMS1. A method (100) for data routing in a distributed control system (DCS) (300) , the method (100) comprising: implementing a plurality of virtual connectors (VCs) (310) , each VC (310) configured to interface between one or more communication channels (312) of the DCS (300) and one or more instrument signals (314) ; monitoring, by a data acquisition module (322) from a command centre (326) , operational parameters for the DCS (300) , the operational parameters comprising information about one or more of available communication channels (312) of the DCS (300) , current statuses of the communication channels (312) of the DCS (300) , priorities for the instrument signals (314) , specific interests for communication channels (312) vis-a-vis the instrument signals (314) , and loading percentages of the communication channels (312) of the DCS (300) ; determining, by a data routing module (324) , signal-to-channel assignments based on the operational parameters for the DCS (300) , with each signal-to-channel assignment designating at least one of the plurality of VCs (310) to interface between specific communication channel (s) of the DCS (300) and specific instrument signal (s) (314) ; communicating, by the data routing module (324) , the signal-to- channel assignments to the plurality of VCs (310) and the command centre (326) ; and executing, by the plurality of VCs (310) and the command centre (326) , the signal-to-channel assignments to dynamically adjust signal-to-channel connections within the DCS (300) .

2. The method (100) of claim 1 further comprising: processing, by the data routing module (324) , the information about the current statuses of the communication channels (312) of the DCS (300) to determine presence of one or more faulty communication channels (312) of the DCS (300) ; and adjusting the signal-to-channel connections to assign one or more spare channels from the available communication channels (312) of the DCS (300) for the instrument signals (314) corresponding to the one or more faulty communication channels (312) of the DCS (300) .

3. The method (100) of claim 1 further comprising: processing, by the data routing module (324) , the information about the loading percentages of the communication channels (312) of the DCS (300) to determine presence of one or more overloaded communication channels (312) of the DCS (300) ; and adjusting the signal-to-channel connections to assign one or more spare channels from the available communication channels (312) of the DCS (300) for the instrument signals (314) corresponding to the one or more overloaded communication channels (312) of the DCS (300) .

4. The method (100) of claim 1 further comprising: processing, by the data routing module (324) , the information about the specific interests for communication channels (312) vis- a-vis the instrument signals (314) to determine particular communication channel (s) of the DCS (300) for specific instrument signal (s) (314) ; andadjusting the signal-to-channel connections to bind the particular communication channel (s) of the DCS (300) for the specific instrument signal (s) (314) .

5. The method (100) of claim 2 further comprising: processing, by the data routing module (324) , the information about the priorities for the instrument signals (314) to determine high-priority instrument signals (314) ; and prioritizing the assignment of the one or more spare channels from the available communication channels (312) of the DCS (300) to the high-priority instrument signals (314) from the instrument signals (314) corresponding to the one or more faulty communication channels (312) of the DCS (300) .

6. The method (100) of claim 1, wherein the step of executing, by the plurality of VCs (310) and the command centre (326) , the signal-to-channel assignments to dynamically adjust signal-to- channel connections within the DCS (300) comprises automatically reconfiguring the connection ( s ) between the one or more communication channels (312) of the DCS (300) and the one or more instrument signals (314) via the plurality of VCs (310) based on the signal-to-channel assignments.

7. The method (100) of claim 6 further comprising sending an acknowledgement by the plurality of VCs (310) to the data routing module (324) confirming the reconfiguration of the connection ( s ) between the one or more communication channels (312) of the DCS (300) and the one or more instrument signals (314) .

8. The method (100) of claim 7 further comprising configuring, by the data routing module (324) , the command centre (326) to update details about the reconfiguration of the connection (s) between the one or more communication channels (312) of the DCS (300) and the one or more instrument signals (314) via the plurality of VCs (310) .

9. A system comprising: one or more processing units; and a memory unit communicatively coupled to the one or more processing units, wherein the memory unit comprises a data routing module (324) stored in the form of machine-readable instructions executable by the one or more processing units, wherein the data routing module (324) is configured to perform method (100) steps for data routing in a distributed control system (DCS) (300) , according to any of the claims 1 to 8.

10. A computer-program product having machine-readable instructions stored therein, which when executed by one or more processing units, cause the one or more processing units to perform a method (100) according to any of the claims 1 to 8.

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