Publish-Subscribe I/O Virtualization for Real-Time Process Control
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Solution Overview
Problem
Current industrial control systems face limitations in scalability, reconfigurability, reliability, and performance due to hardware-driven architectures, which restrict their ability to efficiently manage data and communications, leading to issues with data archiving, controller memory usage, and communication resource utilization.
Innovation Solution
A multi-purpose hardware/software architecture decouples hardware from software, enabling dynamic simulation and run-time process control through a virtualized environment that abstracts I/O operations, allowing for easier scaling, reconfiguration, and improved reliability and availability by using virtual and physical components that cooperate within the MPDSC platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hardware-driven architecture is used in industrial control systems, then the system structure is simple and stable, but the scalability, reconfigurability, and adaptability are limited
Solution Approach 1:
The system is divided into distinct functional modules including simulation environment, run-time environment, configuration database, and deployment tool. Each module operates independently but communicates through standardized interfaces, enabling flexible reconfiguration without redesigning the entire system architecture.
Solution Approach 2:
The control system architecture is designed to serve multiple functions: it can operate in simulation mode for training and testing, switch to run-time mode for actual process control, and support both virtual and physical field devices. This multi-functionality is achieved through a unified architecture that abstracts hardware-specific details.
2Productivity
If virtualized components are introduced to improve scalability and reconfigurability, then the system becomes more flexible, but the device complexity increases
Solution Approach 1:
A configuration database serves as an intermediary layer between the simulation environment, run-time environment, and deployment tools. This centralized repository manages all system configurations, field device parameters, and control logic, simplifying the complexity by providing a single source of truth that all components can access and update.
Solution Approach 2:
The system creates virtual copies of field devices and control systems that can be used in the simulation environment. These virtual devices replicate the behavior and characteristics of physical devices, allowing operators to train and test control strategies without risking actual process disruption, thereby improving scalability without proportionally increasing physical hardware complexity.
3Reliability
If centralized hardware devices are used for process control, then the system is stable and reliable, but the responsiveness and elasticity are reduced
Solution Approach 1:
The system transitions from static hardware configurations to dynamic virtualized environments where control parameters, device configurations, and system architecture can be modified in real-time without physical reconfiguration. This dynamic capability allows the system to adapt quickly to changing process conditions while maintaining reliability through virtualization overhead management.
Data Source
AI summary
A Multi-Purpose Dynamic Simulation and run-time Control platform includes a virtual process environment coupled to a physical process environment, where components/nodes of the virtual and physical process environments cooperate to dynamically perform run-time process control of an industrial process plant and/or simulations thereof. Virtual components may include virtual run-time nodes and/or simulated nodes. The MPDSC includes an I/O Switch which delivers I/O data between virtual and/or physical nodes, e.g., by using publish/subscribe mechanisms, thereby virtualizing physical I/O process data delivery. Nodes serviced by the I/O Switch may include respective component behavior modules that are unaware as to whether or not they are being utilized on a virtual or physical node. Simulations may be performed in real-time and even in conjunction with run-time operations of the plant, and/or simulations may be manipulated as desired (speed, values, administration, etc.). The platform simultaneously supports simulation and run-time operations and interactions/intersections therebetween.