Peer-to-Peer Controller Communication via Virtual I/O Emulation

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Solution Overview

Problem

Conventional Process Automation Systems (PAS) face limitations in integrating first generation and subsequent generation control equipment due to the inability of controllers to exchange process parameter information between different generations, hindering effective communication and integration.

Innovation Solution

Enabling peer-to-peer control signal communications between controllers of different generations by emulating first generation I/O processing modules at subsequent generation controllers, allowing direct communication over first generation I/O networks without requiring changes to the first control system or intermediary devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If controllers of first generation and subsequent generation control systems are used in a conventional PAS, then the system can maintain existing equipment for many decades with significant expense already incurred, but the controllers cannot exchange process parameter information between different generations, hindering integration

Engineering Contradiction:

Improveintegration capability between control system generationsVSAvoidprocess parameter information exchange

Core Design Contradiction:

Adaptability or versatilityVSLoss of information

Solution Approach 1:

The patent implements a virtual I/O processing module that emulates the functionality of first generation I/O processing modules within the subsequent generation controller. This copying approach allows the subsequent generation controller to understand and process communication protocols from first generation controllers, enabling process parameter information exchange without requiring physical first generation I/O processing modules or modifying existing first generation controllers.

Inventive Principle:

Principle #26Copying

2Ease of operation

If conventional PAS architecture is maintained with separate first and subsequent generation control systems, then existing equipment can be preserved, but peer-to-peer communication between controllers of different generations is not enabled

Engineering Contradiction:

Improvepeer-to-peer communication capabilityVSAvoidsystem integration architecture

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the functionality of first generation I/O processing modules into the subsequent generation controller through a virtualization layer. This consolidation eliminates the need for separate physical I/O processing modules for each controller generation, allowing multiple controller generations to share common I/O resources while maintaining their individual communication protocols, thus simplifying the overall system architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The virtual I/O processing module is designed to handle multiple communication protocols and device types simultaneously. It can emulate different first generation I/O processing module functionalities within a single subsequent generation controller, providing universal compatibility across different controller generations and eliminating the need for generation-specific communication infrastructure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If first generation I/O processing modules are physically connected to subsequent generation controllers, then communication can be established, but additional hardware and system changes are required

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidhardware modification requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the physical mechanical connection between first generation I/O processing modules and controllers with a virtual/software-based implementation. The virtual I/O processing module runs as software within the subsequent generation controller, eliminating the need for physical hardware connections, wiring changes, or additional I/O processing modules, while maintaining reliable communication through software-based protocol emulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8996710B2Systems and methods for peer-to-peer control using an input/output network

Publication Date: 2015.03.31 HONEYWELL INTERNATIONAL INC

AI summary

System (200) and method (400) for enabling peer-to-peer communications between controllers (2041, . . . , 204N, 2221, . . . , 222N) of at least two control systems (202, 218). The system (200) include a first control system (FCS) having a first controller (FC) communicatively coupled to a first input/output (I/O) processing module (2121, . . . , 212N) via a first I/O network (2141, . . . , 214N). The first I/O processing module is communicatively coupled to first automation equipment (216). The second control system (SCS) includes a second controller (SC) communicatively coupled to the FC via the first I/O network. The first I/O network provides peer-to-peer communications between the FC and SC. The SC is configured to emulate the first I/O processing module. More particularly, the SC is configured to match an internal I/O configuration with an I/O configuration of the FC.