Self-Descriptive Control Modules for Runtime Industrial Reconfiguration

The patent implements dynamic reconfiguration of I/O and subsystems through a control system that allows runtime modification of system architecture. The controller can dynamically add, remove, or modify I/O points and subsystem connections without requiring physical hardware changes or system shutdowns, enabling the system to adapt to changing process requirements while maintaining operational reliability through controlled transition states.

The control system is divided into independent, modular components including I/O modules, subsystem modules, and a configuration manager. Each module can be individually configured, updated, or replaced without affecting the entire system. This segmentation allows flexible reconfiguration of specific system portions while maintaining stability in other areas, resolving the contradiction between adaptability and reliability.

The patent introduces a configuration manager as an intermediary component that handles all change management operations. This manager provides a unified interface for configuring, updating, and managing system changes, automatically handling the complexity of incremental modifications. Users interact with the simple manager interface rather than directly managing complex system changes, reducing perceived complexity while enabling sophisticated adaptability.

The system manages complexity by parameterizing configuration data and using structured parameter change management. Configuration changes are represented as parameter modifications rather than structural reconfigurations, allowing systematic tracking and management of incremental changes. The configuration manager handles parameter validation, dependency resolution, and change propagation automatically, reducing management burden.

The patent implements virtualization of I/O and subsystem components, creating software-based copies that can run on existing hardware infrastructure. This allows new technological functionalities to be deployed as software modules without requiring expensive new hardware investments. Virtualized components can be replicated and distributed across available resources, improving functionality while leveraging existing capital investments.

The control system is designed with universal, multi-functional components that can perform multiple roles. A single controller platform can host various I/O modules, communication protocols, and processing functions through software configuration rather than dedicated hardware for each function. This multi-functionality reduces the need for specialized expensive equipment while maintaining diverse system capabilities.

The configuration manager performs preliminary validation, simulation, and dependency analysis before implementing system changes. Configuration modifications are tested in a virtual environment first, and only validated changes are deployed to the running system. This preliminary action ensures reliability is maintained while allowing changes to be made without shutdowns, as the system is already prepared for the transition.

The system maintains continuous operational capability during configuration changes by implementing hot-swappable modules and maintaining redundant processing paths. Critical control functions continue to operate while non-critical I/O or subsystem configurations are updated. The configuration manager coordinates changes to maintain continuous useful action, ensuring productivity is not interrupted by implementing necessary system modifications.