Process Controller I/O Pool Migration Without System Redesign
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Solution Overview
Problem
Conventional process control systems with dedicated I/O modules do not allow access to I/O modules by other process controllers, limiting the utilization of I/O modules and requiring a major control system redesign to implement sharing capabilities.
Innovation Solution
The introduction of an I/O software agent that enables existing I/O modules to be part of a shared I/O pool, allowing access to these modules by multiple process controllers without the need for a hardware redesign, by acting as a conduit for any process controller to utilize I/O modules in a remote or centralized I/O cabinet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated I/O modules are assigned to specific process controllers, then each controller has guaranteed access to its assigned I/O modules, but other controllers cannot access those I/O modules and system flexibility is reduced
Solution Approach 1:
An I/O software agent is introduced as an intermediary component that enables multiple process controllers to access the same I/O modules. The agent runs on the process controller and manages I/O channel allocation, allowing dynamic sharing of I/O modules between controllers while maintaining reliable access for each controller to its assigned channels.
2Adaptability or versatility
If I/O module sharing capability is implemented, then system flexibility and controller utilization are improved, but a major control system redesign is required
Solution Approach 1:
The I/O software agent creates a virtual copy of the I/O module interface on each process controller that needs access. Instead of requiring physical reconfiguration or hardware redesign, the agent replicates I/O channel access capabilities through software, allowing multiple controllers to interact with the same physical I/O modules as if they were locally attached.
Solution Approach 2:
The system changes the operational parameters of I/O modules from exclusive dedicated assignment to shared access mode. The I/O software agent manages channel allocation parameters dynamically, allowing the same I/O module to serve multiple controllers by changing access permissions and channel assignment parameters without physical reconfiguration.
3Stability of the object's composition
If existing conventional control systems are used without redesign, then system stability is maintained, but I/O modules cannot be shared between controllers
Solution Approach 1:
The I/O software agent is pre-configured with information about available I/O modules and their channels before runtime. The agent establishes communication pathways and access permissions in advance, allowing existing stable control systems to gain I/O sharing capability without disrupting operational stability or requiring system redesign.
Data Source
AI summary
A process control system includes a first process controller coupled to a first set of input/output (I/O) modules that provided first channels, including an I/O software agent coupled to an I/O module pool that includes a first and at least a second I/O module collectively providing pooled channels. The first channels and the pooled channels are each coupled by a respective field device to first and second processing equipment, respectively. The I/O software agent is configured for enabling addition of the first set of I/O modules to the LO module pool, coupling of a plurality of additional process controllers in a controller pool to the first process controller, and enabling at least one of i) making any of the first channels available to any of the process controllers in the controller pool, and ii) making any of the pooled channels available to the first process controller.