Software-Defined Process Control Visualization for Runtime Reconfiguration
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Solution Overview
Problem
Current industrial process control systems are inflexible and hardware-centric, leading to increased costs for initial engineering and change management, as well as cost overruns and supply-chain delays due to dependence on purpose-built hardware.
Innovation Solution
A software-defined process control system (SDCS) that decouples software and hardware, implementing business logic as logical abstractions on top of computer resources and dynamically managing resources using a hyper-converged infrastructure, including a software-defined networking layer, application layer, and storage layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purpose-built hardware is used for process control systems, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates virtual copies of control system functions through virtual machines and containers that run on standardized hardware. These virtualized control modules replicate the functionality of dedicated hardware controllers while reducing complexity and enabling flexibility. The virtualization layer abstracts control logic from physical hardware, allowing multiple virtual controllers to share underlying hardware resources.
Solution Approach 2:
The patent implements a universal hardware platform that can host multiple different control system functions through software virtualization. Instead of requiring dedicated hardware for each control function, a single standardized hardware infrastructure supports diverse control applications via virtual machines and containers, enabling one hardware system to perform multiple control roles.
2Stability of the object's composition
If purpose-built hardware is used for process control systems, then system stability is improved, but adaptability deteriorates
Solution Approach 1:
The patent implements dynamic resource allocation and orchestration where virtual control modules can be created, moved, scaled, and terminated on demand. The system dynamically manages the lifecycle of virtual machines and containers, allowing control functions to be adapted and reconfigured without hardware changes. This dynamic software-defined approach enables rapid adaptation while maintaining stable control through virtualization abstraction.
Solution Approach 2:
The patent uses virtualization to create software-based copies of control functions that can be replicated and distributed across the infrastructure. These virtual control modules can be copied and deployed to different hardware platforms, enabling consistent control behavior across diverse environments while maintaining system stability through standardized virtual interfaces.
3Adaptability or versatility
If standardized hardware with virtualization is used, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent introduces a virtualization intermediary layer that sits between standardized hardware and control applications. This virtualization layer abstracts hardware complexity from control logic, providing standardized interfaces for deploying and managing control functions. The intermediary manages resource allocation, isolation, and coordination, shielding users from underlying hardware complexity while enabling adaptability.
4Power
If more hardware resources are allocated, then processing capability is improved, but cost increases
Solution Approach 1:
The patent merges multiple control system functions and workloads onto shared hardware infrastructure through virtualization. Multiple virtual control modules share underlying CPU, memory, and I/O resources, improving utilization efficiency and reducing the total hardware required. This consolidation allows the system to achieve high processing capability without proportionally increasing hardware quantity and cost.
Solution Approach 2:
The patent creates a universal hardware platform that serves multiple control functions simultaneously through software virtualization. A single hardware infrastructure supports diverse control applications, eliminating the need for separate dedicated hardware for each function. This multi-functional approach reduces overall hardware requirements and cost while maintaining adequate processing capability across all control functions.
Data Source
AI summary
A software defined (SD) process control system (SDCS) implements controller and other process control-related business logic as logical abstractions (e.g., application layer services executing in containers, VMs, etc.) decoupled from hardware and software computing platform resources. An SD networking layer of the SDCS utilizes process control-specific operating system support services to manage the usage of the computing platform resources and the creation, deletion, modifications, and networking of application layer services with devices disposed in the field environment and with other services, responsive to the requirements and needs of the business logic and dynamically changing conditions of SDCS hardware and/or software assets during run-time of the process plant (such as performance, faults, addition/deletion of hardware and/or software assets, etc.). A visualization system of the SDCS provides a user with a view as to the state of the SDCS as currently configured/running on the computing platform to enable a user to view currently configured interrelationships between logical elements of the control system and other logical and/or physical elements of the control system. The visualization system also provides performance metrics of the system as currently configured to enable a user to understand the operational health of the control system as currently configured.