Controller Function Library for Legacy-Compatible Migration
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Solution Overview
Problem
The challenge of maintaining compatibility and seamless operation when replacing or upgrading controllers in industrial process control systems, particularly due to differences in legacy and modern control functions, leads to complex re-engineering, increased costs, and prolonged downtime.
Innovation Solution
A data processing device and method that maintains a function library with both legacy and improved control functions, allowing seamless execution based on device settings, thereby reducing the need for re-engineering and preserving user experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If legacy controllers are replaced with newgen controllers, then control functionality and performance are improved, but compatibility with legacy components deteriorates
Solution Approach 1:
The patent introduces a compatibility layer or translation mechanism that acts as an intermediary between newgen controllers and legacy control functions. This layer enables the newgen controller to execute legacy control routines while maintaining compatibility with existing legacy components, thus resolving the contradiction between improved functionality and maintained compatibility
Solution Approach 2:
The patent segments the control functions into legacy control routines and newgen control functions, allowing them to operate independently within the same system. This segmentation enables the newgen controller to selectively execute legacy routines when compatibility is required while utilizing newgen functions for enhanced performance
2Reliability
If legacy control functions are executed on newgen controllers, then compatibility is maintained, but system complexity increases
Solution Approach 1:
The patent extracts legacy control functions into separate, isolated execution environments or virtual machines within the newgen controller. This extraction allows legacy functions to run independently without interfering with the newgen controller's native architecture, thereby maintaining compatibility while minimizing the impact on system complexity
3Reliability
If full re-engineering is performed to achieve compatibility, then compatibility is improved, but migration time and costs increase
Solution Approach 1:
The patent implements preliminary compatibility testing and validation mechanisms that are built into the newgen controller architecture before deployment. This preliminary action ensures that legacy control functions can be executed without requiring extensive re-engineering or validation during the migration process, thereby reducing migration time and costs
Data Source
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AI summary
This disclosure provides a device (154) and method (300) for implementing legacy and improved control functions in controllers (156), including but not limited to in industrial control systems and other systems. A method includes maintaining (302), by a device (154) having a controller (156) and a memory (158), a function library (210) having a plurality of legacy control functions (220) and a plurality of improved control functions (222). The method includes receiving (304) a process to be executed by the controller (156). The method includes, when calling a function of the process, determining (306) whether a device setting indicates that the function is to be executed by one of the plurality of improved control functions (222). The method includes, when the device setting indicates that the function is to be executed by one of the plurality of improved control functions (222), executing (308) the function using the one of the improved control functions (222), and when the device setting does not indicate that the function is to be executed by one of the plurality of improved control functions (222), executing (310) the function using one of the legacy control functions (220).