Process Control PC Virtualization for Real-Time Reliability
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Solution Overview
Problem
Process control systems face challenges in maintaining real-time communication and high reliability due to the limitations of universal PCs and Ethernet transmission standards, which are affected by frequent OS and hardware changes, leading to increased costs and difficulties in maintaining systems over a lengthy plant lifetime.
Innovation Solution
A process control system is designed with a PC that includes a virtualization unit and a real-time communication unit operating independently, utilizing a host OS to manage guest OS and application software, and featuring a real-time communication unit with functions for data checking, retransmission, path diagnosis, and redundant network switching, eliminating the need for dedicated network cards and ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a universal PC with Ethernet is used for process control, then cost is reduced and adaptability to technological changes is improved, but real-time communication reliability deteriorates
Solution Approach 1:
The PC is divided into two independent communication units: a real-time communication unit dedicated to control network communication and a general communication unit for other purposes. This segmentation allows the real-time functions to be isolated from the non-real-time Ethernet operations, ensuring that cost-effective universal PCs can provide reliable real-time communication without interference from general Ethernet traffic.
2Reliability
If dedicated interface cards for real-time communication are installed, then real-time property is improved, but device complexity and cost increase
Solution Approach 1:
The real-time communication unit is integrated within the universal PC rather than using separate dedicated hardware cards. This merging approach combines the real-time communication capability with the existing PC platform, reducing overall device complexity while maintaining real-time performance through software-based isolation and prioritization mechanisms.
3Ease of manufacture
If universal Ethernet is used instead of dedicated control networks, then cost is reduced, but real-time communication capability deteriorates
Solution Approach 1:
The communication interface is segmented into dedicated real-time and general Ethernet portions. The real-time communication unit handles control network traffic with guaranteed performance, while the general Ethernet interface handles non-critical data. This allows the system to use cost-effective universal Ethernet hardware while preserving real-time communication capabilities through logical separation and prioritization.
Data Source
AI summary
A process control system includes a PC that is to be connected to a redundant network. The PC comprises a virtualization unit, and a real-time communication unit configured to operate as a separate process independent of the virtualization unit.