Online Node Reconfiguration in Process Control Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current process control systems face challenges during online reconfiguration, as changes can lead to unforeseen and undesirable impacts on runtime behavior and dynamics, potentially resulting in production losses due to their controller-centric architecture and lack of efficient configuration processes.
Innovation Solution
A method and node manager for online reconfiguration of nodes in a process control system, where each component is a separate executable running in a separate operating system process, allowing for the creation of new configuration entities, synchronization of runtime data, and replacement of existing entities, enabling efficient and supervised reconfiguration of controllers, gateways, and devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If online reconfiguration is performed in controller-centric architecture, then configuration flexibility is improved, but system stability deteriorates due to unexpected behavior and side effects
Solution Approach 1:
The system divides the controller into multiple independent configuration entities, each responsible for specific configuration aspects. This segmentation allows individual entities to be modified without affecting the entire system, enabling flexible reconfiguration while maintaining overall system stability through isolated changes.
Solution Approach 2:
The system performs preliminary validation and simulation of configuration changes before applying them to the running controller. Configuration entities are tested in a virtual environment first, and only validated changes are deployed, preventing unexpected behavior and side effects during online reconfiguration.
2Productivity
If controller executes control logic applications with I/O interfaces, then control functionality is improved, but configuration complexity increases due to hardware topology and implementation knowledge requirements
Solution Approach 1:
The patent introduces configuration entities as intermediary components that abstract the complexity of hardware topology and I/O interface configurations. These entities provide a standardized interface for configuration, eliminating the need for direct knowledge of underlying hardware implementations while maintaining full control functionality.
Solution Approach 2:
The configuration entities are designed as universal, reusable components that can manage multiple I/O interfaces and control logic applications through standardized mechanisms. This multi-functionality reduces configuration complexity by providing a unified approach rather than requiring separate handling for each hardware component.
3Productivity
If configuration changes are applied during runtime, then system availability is improved, but risk of production losses increases due to unforeseen impacts on runtime behavior
Solution Approach 1:
The system performs preliminary validation, simulation, and performance evaluation of configuration changes in a virtual environment before applying them to the running system. This advance testing identifies potential harmful effects beforehand, allowing safe online reconfiguration without risking production losses.
Solution Approach 2:
The system implements feedback mechanisms that continuously monitor runtime behavior during and after configuration changes. Performance metrics and system behavior are evaluated in real-time, and if unexpected impacts are detected, the system can automatically rollback changes, preventing production losses while maintaining high availability.
Data Source
AI summary
A method for online reconfiguration of a node in a process control system including components. Each component is a separate executable running in a separate operating system process as provided by a real time operating system of the node. A method is performed by a node manager of the node to be reconfigured. The method includes triggering, based on new configuration data and whilst running the at least one of the components to be reconfigured, creation of a new configuration entity for each of the at least one of the components to be reconfigured, the creating involving implementing, by each new configuration entity, a part of the reconfiguration corresponding to its component to be reconfigured. The method includes triggering synchronization of runtime data in each new configuration entity with runtime data of its corresponding existing configuration entity. The method includes triggering replacement of the existing configuration entity with its new configuration entity and thereby reconfiguring the node.