Modular Distributed Control Nodes for Interoperable Industrial Systems
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Solution Overview
Problem
Current distributed control systems (DCS) are limited by proprietary architectures that restrict interoperability, require costly upgrades, and lack flexibility, leading to inefficient resource utilization and competitive disadvantages for manufacturing facilities, especially in the petrochemical industry.
Innovation Solution
A modular, interoperable DCS architecture utilizing distributed control nodes (DCNs) connected via high-speed Layer 3 Ethernet switches, with a standard software runtime providing control application level communication and function block execution services, allowing for the integration of innovative applications and flexible scaling across manufacturing lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proprietary application protocols are used in DCS, then system reliability is improved, but interoperability and adaptability deteriorate
Solution Approach 1:
The patent introduces an intermediary translation layer that converts proprietary control protocols into standard web services (REST, SOAP,publish-subscribe). This mediator enables communication between legacy control systems and modern IT systems without requiring changes to the original reliable control protocols, thus maintaining reliability while achieving interoperability.
Solution Approach 2:
The DCS system is enhanced with universal web service interfaces that allow it to communicate with multiple types of systems (IT systems, mobile devices, cloud platforms) using standard protocols. This multi-functionality enables the same control system to serve both traditional industrial communication needs and modern digitalization requirements.
2Stability of the object's composition
If centralized control architecture is used, then system stability is improved, but scalability and flexibility deteriorate
Solution Approach 1:
The patent segments the centralized control architecture into distributed microservices that can independently deploy and scale. Each control function is broken into separate service components that communicate through standard web protocols, allowing individual services to be scaled, updated, or replaced without affecting the entire system stability.
Solution Approach 2:
The system adds a new dimensional layer by introducing web service interfaces between the control layer and IT systems. This creates a multi-dimensional architecture where traditional vertical control hierarchy is complemented by horizontal web service communication, enabling scalability without compromising vertical stability.
3Reliability
If proprietary hardware components are required, then system reliability is improved, but cost and ease of manufacture deteriorate
Solution Approach 1:
The patent replaces proprietary hardware interfaces with software-based web service interfaces. Instead of requiring specialized hardware components for communication, the system uses standard software protocols (REST, SOAP, publish-subscribe) that can run on commodity hardware, dramatically reducing manufacturing costs while maintaining communication reliability.
Solution Approach 2:
The system creates virtual copies of proprietary interface functionality through software emulation. Rather than requiring physical proprietary hardware, the same communication capabilities are replicated through software implementations of standard web services, enabling compatibility with off-the-shelf hardware.
4Adaptability or versatility
If frequent system replacements are performed, then technology currency is improved, but productivity and loss of time deteriorate
Solution Approach 1:
The patent creates a dynamic architecture where individual control services can be independently updated, deployed, and scaled. This allows the system to progressively adopt new technologies and standards without requiring complete system replacements, maintaining technology currency while ensuring continuous operational productivity.
Solution Approach 2:
The web service interface layer ensures continuous operation during technology transitions. By decoupling legacy control systems from modern IT systems through standardized protocols, the system maintains uninterrupted control functionality while enabling gradual technology updates and upgrades.
Data Source
AI summary
A distributed control system (DCS) for controlling an industrial process using a plurality of distributed control nodes (DCNs) can include a plurality of Device DCNs, each Device DCN including an I/O interface coupled with a field device for single channel input or output, a plurality of Application DCNs, and one or more Ethernet switches. The plurality of Device DCNs and the plurality of Application DCNs can be adapted to host a software runtime and communicatively coupled via the one or more Ethernet switches. The DCS architecture can include of two types of DCNs; Application DCNs and Device DCNs. The software runtime can be configured to selectively provide control application level communication and function block execution services.