Gateway Logical Mapping for Controller Migration Without Shutdown
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Solution Overview
Problem
Existing industrial process control and automation systems face significant challenges when replacing legacy controllers, as it often requires shutting down facilities and incurring substantial monetary losses due to the need for extensive modifications to higher-level controllers and user interfaces.
Innovation Solution
A gateway that provides a logical model mapped to independent underlying networks, allowing concurrent access for supervisory devices to both legacy and advanced controllers, enabling seamless migration without facility shutdowns by emulating legacy protocols over advanced networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a new controller is installed to replace a legacy controller, then the system can use advanced control capabilities, but the facility must be shut down and significant modifications are required to higher-level controllers and user interfaces
Solution Approach 1:
The gateway acts as an intermediary device that connects both the legacy controller network and the new controller network to the supervisory system. It translates communication protocols between the old and new controllers, allowing the supervisory system to interact with both controllers simultaneously during migration without requiring facility shutdown or extensive modifications to higher-level controllers.
Solution Approach 2:
The gateway is installed and configured before the legacy controller is decommissioned. It is pre-configured with communication protocols for both the legacy and new controller networks, enabling seamless transition. The supervisory system is also prepared with updated communication pathways through the gateway before the actual controller replacement occurs.
2Adaptability or versatility
If legacy controllers are replaced with new controllers, then advanced control functions are available, but custom user interfaces and control applications must be replaced
Solution Approach 1:
The gateway emulates the communication interface and data structure of the legacy controller when communicating with the supervisory system. It creates a virtual copy of the legacy controller's interface, allowing existing custom user interfaces and control applications to continue functioning without modification while the physical legacy controller is replaced with an advanced new controller.
3Adaptability or versatility
If a cutover of legacy devices to replacement devices is performed, then the new controller can be deployed, but the facility must be shut down for a period of time
Solution Approach 1:
The gateway enables continuous operation of the facility during controller migration by maintaining active communication pathways to both the legacy and new controllers simultaneously. The supervisory system can continuously monitor and control processes through the gateway, which routes commands and data appropriately regardless of which controller is currently active, eliminating the need for facility shutdown during the transition.
Data Source
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AI summary
An apparatus includes a first interface (206) configured to communicate over a first industrial process control network (103) using a first protocol. The apparatus also includes a second interface (208) configured to communicate over a second industrial process control network (110) using a second protocol. The apparatus further includes a third interface (204) configured to communicate with at least one supervisory device (112, 114, 116, 118, 120) over a third network (106). In addition, the apparatus includes at least one processing device (214) configured to provide concurrent access for the at least one supervisory device to process control devices (102, 102') coupled to the first and second industrial process control networks during a migration of process control devices (102) that use the first protocol to process control devices (102') that use the second protocol.