Networked I/O Control Simulation for Open Process Systems
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Solution Overview
Problem
Open process control systems face challenges in implementing a simulation function without specialized controllers, as they require I/O connection devices and general-purpose controllers to be prepared, and there is a need for a simulation function that can operate in multivendor environments with network compatibility.
Innovation Solution
A control device with a communication unit, acquisition unit, and calculation unit that communicates with I/O connection devices and information processing devices via a network, allowing it to acquire device information and perform control calculations, even if some actual equipment is not prepared, and enabling the simulation function to be implemented in an open process control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a general purpose controller is used instead of a specialized controller in an open process control system, then the cost is reduced and system flexibility is improved, but the ability to perform simulation functions is compromised because simulation requires actual I/O connection devices and equipment to be prepared
Solution Approach 1:
The patent creates a virtual copy of the I/O connection device through software simulation. The simulation I/O connection device replicates the functionality of actual hardware I/O devices, allowing the control system to perform simulation operations without requiring physical equipment. This virtual copying enables the general purpose controller to achieve simulation capabilities that were previously only available with specialized controllers and actual hardware.
2Loss of time
If simulation is performed without actual I/O connection devices prepared, then operation tests can be conducted earlier, but the system requires additional software components and virtualization capabilities that increase system complexity
Solution Approach 1:
The patent introduces a simulation I/O connection device as an intermediary layer between the control unit and the actual physical I/O devices. This intermediary software component mediates all I/O operations by intercepting control commands and generating simulated responses without requiring actual hardware connection. The intermediary approach enables early operation testing while managing system complexity through a standardized software interface.
3Adaptability or versatility
If a simulation function is implemented in an open process control system with multivendor environments, then vendor independence is improved, but ensuring compatibility across different I/O connection devices and networks becomes more difficult
Solution Approach 1:
The patent implements a universal simulation I/O connection device that can emulate multiple types of actual I/O devices from different vendors through a single software platform. The simulation device possesses multi-functionality, capable of replicating various hardware interfaces and communication protocols, thereby enabling vendor-independent operation testing. This universality approach allows the system to work with different I/O connection devices and networks without requiring vendor-specific simulation software.
Data Source
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AI summary
A control device (100) includes a communication unit (110), an acquisition unit (121), and a calculation unit (122). The communication unit (110) performs communication with an I/O connection device (200) where an I/O device (400) is connected and an information processing device (300), via a network. The acquisition unit (121) acquires device information related to the I/O device (400) from at least one of a first storage unit (222) included in the I/O connection device (200) and storing the device information and a second storage unit (320) included in the information processing device (300) and storing the device information. The calculation unit (122) performs control calculation related to the I/O device by using the device information (400).