I/O Server Selection of Active Controller Outputs in SDCS
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Solution Overview
Problem
Current industrial process control systems are inflexible and hardware-centric, leading to increased costs and complexity in engineering and change management, as well as susceptibility to cost overruns and supply-chain delays due to their dependence on purpose-built hardware.
Innovation Solution
A software-defined process control system (SDCS) that decouples software and hardware, implementing business logic as logical abstractions on top of computer resources and dynamically managing resources using techniques such as software-defined networking, application layers, and storage layers to support dynamic demands during runtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purpose-built hardware is used for process control systems, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses virtualization to create virtual copies of control functions and I/O devices. Virtual I/O devices and virtual controllers are implemented as software abstractions that replicate the functionality of physical hardware, allowing multiple virtual instances to run on shared physical infrastructure. This reduces hardware complexity while maintaining control functionality through software-based copying of control logic and device interfaces.
Solution Approach 2:
The patent implements a universal virtualization platform that can host multiple different control functions, I/O device types, and controller instances on a single physical infrastructure. The virtual I/O server and virtual controller architecture provides multi-functionality by allowing diverse control applications to share common hardware resources, thereby reducing overall system complexity while maintaining reliability through virtualized service delivery.
2Reliability
If purpose-built hardware is used for process control systems, then control functionality is ensured, but manufacturing cost and supply chain dependency increase
Solution Approach 1:
The patent replaces physical hardware-based control systems with software-defined control functions running on virtualized infrastructure. Instead of dedicated physical I/O devices and controllers, the system uses virtual I/O servers and virtual controllers implemented as software layers that abstract control functionality from physical hardware. This substitution reduces manufacturing costs by eliminating the need for specialized hardware components while maintaining control functionality through software implementation.
Solution Approach 2:
The virtualization platform provides universal support for multiple control functions and I/O device types through software, eliminating the need for separate purpose-built hardware for each control application. A single physical infrastructure can be configured to support diverse control functions through virtualization, significantly reducing manufacturing costs and supply chain dependencies while ensuring control functionality through software-based implementation.
3Reliability
If multiple active controller outputs are connected to field devices, then fault tolerance is improved, but signal conflict and device damage risk increase
Solution Approach 1:
The patent introduces a virtual I/O server as an intermediary layer between multiple virtual controllers and field devices. This virtual I/O server manages and coordinates output signals from multiple active controllers, ensuring that only one controller's output is actively connected to physical field devices at any given time. The virtual I/O server acts as a mediator that prevents signal conflicts by controlling the switching between different controller outputs, thereby maintaining fault tolerance while eliminating harmful signal conflicts that could damage field devices.
4Adaptability or versatility
If traditional I/O devices are used for communication between controllers and field devices, then protocol support is improved, but device complexity and inflexibility increase
Solution Approach 1:
The patent replaces physical I/O devices with virtual I/O devices implemented as software components. The virtual I/O server provides protocol support through software-based communication interfaces that can be configured to support multiple field device protocols without requiring physical hardware changes. This substitution reduces I/O device complexity by consolidating protocol handling capabilities into software while maintaining adaptability to support diverse field device communication protocols through virtualized interface implementation.
Data Source
AI summary
An I/O server service interacts with multiple containerized controller services each implementing the same control routine to control the same portion of the same plant. The I/O server service may provide the same controller inputs to each of the containerized controller services (e.g., representing measurements obtained by field devices and transmitted by the field devices to the I/O server service). Each containerized controller service executes the same control routine to generate a set of controller outputs. The I/O server service receives each set of controller outputs and forwards an “active” set to the appropriate field devices. The I/O server service and other services, such as an orchestrator service, may continuously evaluate performance and resource utilization in the control system, and may dynamically activate and deactivate controller services as appropriate.