Virtual DCS Topology Replication for Control Logic Validation
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Solution Overview
Problem
Testing control logic for distributed control systems in industrial plants is laborious and costly, often leading to delays and errors due to the need for separate hardware and software installations in simulation environments, which are mostly manual and prone to human errors.
Innovation Solution
A computer-implemented method for creating a virtual deployment of a distributed control system using a declarative and/or imperative description to simulate the industrial process, incorporating an I/O simulator to provide realistic sensor and actor data, allowing for the testing of control logic in a virtual environment that mirrors the physical setup, thereby reducing costs and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate simulation environment with hardware and software installation is set up to test control logic, then control logic testing can be performed, but the process becomes laborious, costly, and prone to human errors
Solution Approach 1:
The patent creates a virtual copy of the distributed control system using virtual machines that replicate the hardware and software configuration. This virtual deployment allows control logic testing without requiring physical hardware setup, thereby maintaining testing reliability while eliminating the complexity and errors associated with manual hardware installation and configuration
Solution Approach 2:
The patent replaces the mechanical/physical system of hardware installation and configuration with a software-based virtualization system. By substituting physical hardware setup with virtual machine deployment, the system eliminates manual labor, reduces human errors, and simplifies the testing environment while maintaining the ability to thoroughly test control logic
2Reliability
If control logic is tested late in the commissioning phase when servers and controllers are already installed, then the actual production setup is complete, but production time is delayed when errors are found and need to be fixed
Solution Approach 1:
The patent enables control logic testing to be performed in advance during the design phase using virtual deployments. By conducting comprehensive testing before physical hardware is installed and before production begins, any errors can be identified and corrected early, ensuring production readiness is achieved without delays to the actual production timeline
3Reliability
If a separate hardware and software installation is maintained for simulation environment, then control logic testing can be performed, but labor and costs increase significantly
Solution Approach 1:
The patent creates a virtual deployment system that can serve multiple functions: it can be used for control logic testing, for validating the distributed control system configuration, and as a platform for various types of simulations. This multi-functional virtual environment eliminates the need for separate dedicated testing hardware, thereby reducing overall setup effort and costs while maintaining comprehensive validation capabilities
Data Source
AI summary
A method for creating a virtual deployment of a distributed control system (DCS) for a given industrial process, comprising: providing a topology of the assets executing the industrial process, as well as control logic for controlling these assets; providing at least one I/O simulator that is configured to supply data; determining a topology of devices that form part of the DCS; establishing based at least in part on this topology of devices, at least one declarative and/or imperative description of the DCS that characterizes multiple devices of the DCS, their placement, and their connections; creating virtual instances of the devices of the DCS and their connections in a chosen environment.