Hierarchical SDCS Containers for Flexible Process Plant Control

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Solution Overview

Problem

Current industrial process control systems are inflexible and hardware-centric, leading to increased costs and delays in installations and expansions due to dependence on purpose-built hardware, and lack the flexibility seen in IT systems where hardware requirements are abstracted from business logic.

Innovation Solution

A software-defined process control system (SDCS) that decouples software and hardware, utilizing a hyper-converged infrastructure with a software-defined networking, application, and storage layer to dynamically manage resources and support dynamic process control demands, employing containers and orchestrators for load balancing and fault tolerance, and includes security and discovery services for seamless operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If purpose-built hardware is used for process control systems, then system reliability is improved, but device complexity and installation costs increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the process control system into virtualized functional modules (process control modules, I/O modules, communication modules) that can be independently deployed and managed on standard hardware infrastructure, reducing overall system complexity while maintaining reliability through modular architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements a universal hardware platform that can host multiple different process control functions and applications simultaneously through virtualization, allowing standard servers to replace specialized purpose-built hardware while maintaining system reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If purpose-built hardware is used for process control systems, then system stability is improved, but adaptability and flexibility worsen

Engineering Contradiction:

Improvesystem stabilityVSAvoidsystem adaptability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent implements dynamic resource allocation and load balancing mechanisms that allow the system to adapt to changing process control demands in real-time, with virtualized modules that can be dynamically instantiated, migrated, or scaled on standard hardware infrastructure

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent enables parameter changes and system reconfiguration through software-defined parameters and configurations rather than hardware changes, allowing the same physical infrastructure to support different process control scenarios by modifying virtualized module parameters and relationships

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If standard hardware infrastructure is used with virtualization, then adaptability is improved, but system reliability may worsen

Engineering Contradiction:

Improvesystem adaptabilityVSAvoidsystem reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements fault tolerance mechanisms including redundant virtualized process control modules, checkpointing, and automatic failover capabilities that cushion against potential failures on standard hardware infrastructure, maintaining system reliability while using adaptable virtualized architecture

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent implements continuous health monitoring and feedback mechanisms that track the status of virtualized modules and underlying hardware, enabling automatic remediation actions and maintaining system reliability through real-time feedback loops on standard infrastructure

Inventive Principle:

Principle #23Feedback

4Ease of operation

If hardware requirements are abstracted from business logic, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improveease of operationVSAvoidsoftware complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary virtualization layer with standardized APIs and abstraction interfaces that shield operators from underlying hardware complexity, allowing business logic to be configured and operated without direct hardware knowledge while the virtualization infrastructure handles hardware abstraction automatically

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12585237B2Systems and methods for hierarchical organization of software defined process control systems for industrial process plants

Publication Date: 2026.03.24 FISHER ROSEMOUNT SYST INC

AI summary

A process control system includes a plurality of field devices operating to control a process. A communication infrastructure couples the field devices to a software-defined control system (SDCS) that receives data from the field devices and transmits instructions to the field devices. A data cluster, executing the SDCS, includes a plurality of computing nodes, each of which includes a processor executing an operating system, a memory, and a communication resource coupled to one or more other computing nodes in the data cluster. First and second containers, each of which is an isolated execution environment, are instantiated on a first computing node within the operating system of the first computing node. The second container is instantiated within the first container. The first and second containers correspond to levels of a hierarchical structure of the SDCS.