Virtual Control Nodes With I/O Switching for Real-Time Load Balancing
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Solution Overview
Problem
Current industrial control systems face limitations in scalability, reconfigurability, reliability, and performance due to hardware-driven architectures, which restrict their ability to efficiently manage data and I/O operations, leading to issues with data archiving, communication resource utilization, and system responsiveness.
Innovation Solution
A multi-purpose hardware/software architecture decouples hardware from software, enabling dynamic simulation and run-time process control through a virtualized environment that abstracts I/O operations, allowing for easier scaling, reconfiguration, and improved reliability and performance by using virtual and physical components that cooperate within the MPDSC platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware-driven architecture is used, then system structure is simple and reliable, but scalability and reconfigurability are limited
Solution Approach 1:
The system segments control functions into virtual nodes that can be independently deployed, scaled, and configured. Each virtual node represents a discrete functional unit that can be managed separately, enabling modular scalability and reconfigurability without requiring complete system redesign.
Solution Approach 2:
The patent introduces a virtualization dimension by decoupling software from hardware, creating a layered architecture where virtual nodes operate independently of physical constraints. This additional abstraction layer enables dynamic reconfiguration and scaling without being bound by traditional hardware architecture limitations.
2Adaptability or versatility
If virtualized environment is implemented, then scalability and reconfigurability improve, but system complexity increases
Solution Approach 1:
The patent introduces a virtualization management layer that acts as an intermediary between physical hardware and virtual nodes. This mediator handles the complexity of resource allocation, node deployment, and configuration management, shielding users from underlying system complexity while enabling scalable and reconfigurable operations.
3Ease of operation
If data is archived in centralized databases, then data management is simplified, but communication resource utilization deteriorates
Solution Approach 1:
The system implements local data caching at virtual node level, allowing frequently accessed process data to be stored locally rather than continuously fetched from centralized databases. This reduces communication overhead and resource utilization while maintaining ease of data access for control operations.
4Productivity
If traditional hardware architecture is used, then system reliability is maintained, but responsiveness and performance deteriorate
Solution Approach 1:
The patent creates virtual copies of control functions that can execute in parallel with physical hardware. These virtual node instances provide enhanced responsiveness by handling data processing and control logic in the virtualized environment, while the underlying hardware continues to provide reliable physical I/O operations.
Data Source
AI summary
A Multi-Purpose Dynamic Simulation and run-time Control platform includes a virtual process environment coupled to a physical process environment, where components/nodes of the virtual and physical process environments cooperate to dynamically perform run-time process control of an industrial process plant and/or simulations thereof. Virtual components may include virtual run-time nodes and/or simulated nodes. The MPDSC includes an I/O Switch which delivers I/O data between virtual and/or physical nodes, e.g., by using publish/subscribe mechanisms, thereby virtualizing physical I/O process data delivery. Nodes serviced by the I/O Switch may include respective component behavior modules that are unaware as to whether or not they are being utilized on a virtual or physical node. Simulations may be performed in real-time and even in conjunction with run-time operations of the plant, and/or simulations may be manipulated as desired (speed, values, administration, etc.). The platform simultaneously supports simulation and run-time operations and interactions/intersections therebetween.