Loop-by-Loop Control Strategy Migration Without Process Downtime
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Solution Overview
Problem
Existing industrial process control and automation systems face challenges in upgrading from legacy control systems to modern systems without causing downtime, requiring rewiring or altering hardware, and struggling to identify the root cause of process control issues during bulk migration.
Innovation Solution
A method and apparatus for on process loop-by-loop control strategy migration from legacy to modern control systems, utilizing a single microprocessor to host both legacy and modern control execution environments, allowing parallel operation and migration without hardware changes, and employing a translator to convert legacy source code to modern code.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bulk migration of control strategies is performed from legacy to modern control systems, then modernization is achieved, but system downtime and loss of process control occur
Solution Approach 1:
The patent divides the control system into multiple independent control modules that can be migrated individually. Each control module operates independently, allowing selective migration from legacy to modern control system without affecting the entire system. This segmentation enables continuous operation of non-migrated modules while maintaining process control continuity during the migration process.
Solution Approach 2:
The patent implements a parallel control module that is pre-configured and ready to take over control functions before the actual migration occurs. The parallel control module is prepared in advance with all necessary control strategies and parameters, allowing seamless switching from legacy to modern control system without interruption to process control.
2Adaptability or versatility
If legacy control systems are replaced with modern control systems, then system capabilities are improved, but hardware reconfiguration and rewiring are required
Solution Approach 1:
The patent designs the control module to be universal and hardware-agnostic, capable of operating with different hardware configurations without requiring physical reconfiguration. The control module uses standardized communication interfaces and can be deployed across various hardware platforms, eliminating the need for rewiring or hardware changes during migration.
Solution Approach 2:
The patent replaces physical hardware reconfiguration with software-based control module deployment. Instead of mechanically reconfiguring hardware connections and rewiring systems, the migration is achieved through software installation and configuration of control modules, significantly reducing hardware complexity and installation effort.
3Productivity
If control strategies are migrated in bulk, then migration speed is increased, but identification of individual control loop issues becomes difficult
Solution Approach 1:
The patent segments the control system into individual controllable modules that can be migrated and tested independently. This segmentation allows operators to identify and troubleshoot specific control loop issues without affecting the entire system, making problem detection and resolution straightforward even during bulk migration operations.
Solution Approach 2:
The patent implements comprehensive feedback mechanisms that monitor the status and performance of each control module individually. Real-time feedback on control loop performance, error states, and operational parameters enables rapid identification and diagnosis of issues during migration, maintaining high productivity while ensuring quality control.
Data Source
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AI summary
A method comprises controlling, via a first process of a process controller, the industrial process, wherein the process controller is coupled, via a communication path, to an input/output (I/O) link execution environment manager (IOL EE), the process controller comprising a microprocessor configured to host a first control execution environment to support a first set of I/O functions and corresponding control execution functions to control the industrial process; migrating a subset of the first set of I/O functions and corresponding control execution functions to a second process of the process controller to form a second set of I/O functions and corresponding control functions, wherein the microprocessor is configured to host a second control execution environment to support the second set of I/O functions and the corresponding control execution functions to control the industrial process; and controlling, via second process.