Legacy Controller Virtualization for Cross-OS Configuration Simulation
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Solution Overview
Problem
Legacy Level 1 controllers in distributed control systems are difficult to configure and simulate due to their outdated design and incompatibility with modern operating systems, making it challenging to preconfigure them before installation and manage complex industrial processes efficiently.
Innovation Solution
A system and method for virtualizing a legacy Level 1 controller by translating application source code to executable instructions for a simulation device with a different operating system, using emulation and custom scheduling to simulate the legacy operating system, allowing for the determination and saving of configuration data for the legacy controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If legacy Level 1 controllers are used in distributed control systems, then compatibility with modern operating systems is lost, but maintaining legacy systems preserves existing control functionality
Solution Approach 1:
The patent creates a virtual copy of the legacy Level 1 controller that runs on modern operating systems. This virtual controller replicates the functionality of the original legacy controller while being compatible with contemporary OS environments, thus resolving the contradiction between OS compatibility and functional reliability
Solution Approach 2:
The patent introduces a translation layer or intermediary software that bridges the legacy controller code and modern operating system interfaces. This intermediary enables the legacy control logic to communicate effectively with modern OS APIs and system calls, maintaining functionality while achieving OS compatibility
2Ease of operation
If legacy controller code is directly executed on modern systems, then configuration complexity increases, but translation and emulation add computational overhead
Solution Approach 1:
The patent performs translation of legacy controller code to modern OS-compatible code during the configuration phase, before the controller is deployed. This preliminary translation action simplifies the configuration process by eliminating the need for complex runtime translation, while the translation complexity is confined to the setup phase rather than ongoing operation
3Loss of time
If legacy controllers are configured before installation, then deployment time is reduced, but simulation and testing become more difficult
Solution Approach 1:
The patent creates a virtual simulation environment that replicates the legacy controller's behavior, enabling configuration, testing, and validation to be performed on the virtual copy before deploying to the physical controller. This allows pre-installation configuration to proceed smoothly while simulation and testing remain feasible through the virtual model
Data Source
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AI summary
A method includes translating (701) at least one application source code file (302) associated with a legacy controller (106, 114, 122, 130, 138) in a distributed control system (100) to instructions executable by a controller simulation computing device (320, 800), wherein the legacy controller is associated with a legacy operating system and the controller simulation computing device is associated with a second operating system different from the legacy operating system. The method also includes simulating (703) operation of the legacy controller using the instructions and an emulation (322) of the legacy operating system in the controller simulation computing device. The method further includes determining (705) configuration data for the legacy controller during the simulated operation of the legacy controller. In addition, the method includes saving (707) the configuration data to a configuration data file (324).