Loop-by-Loop Control Strategy Migration on Shared Process Controllers
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Solution Overview
Problem
Existing industrial process control and automation systems face challenges in upgrading from legacy to modern control systems without causing downtime, requiring rewiring or altering hardware, and identifying the root cause of process control issues during bulk migration.
Innovation Solution
A method and apparatus for on process loop-by-loop control strategy migration from legacy to modern control systems, utilizing a single microprocessor to host both control execution environments, allowing parallel operation and direct access to I/O modules, and employing a translation mechanism for source code compatibility, enabling seamless migration without hardware changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bulk migration of control strategies is performed from legacy to modern control systems, then migration efficiency is improved, but it becomes difficult to identify the root cause of process control issues and requires system downtime
Solution Approach 1:
The patent divides the bulk migration process into individual loop-level migrations. Each control loop is migrated separately while the system remains operational, allowing operators to identify and isolate specific loops that may be causing process control issues. This segmentation enables granular troubleshooting and root cause identification without requiring complete system shutdown or bulk migration.
2Reliability
If legacy control systems are upgraded to modern control systems, then system reliability and functionality are improved, but hardware must be altered or rewired causing downtime
Solution Approach 1:
The patent introduces a communication path translation mechanism that acts as an intermediary between legacy I/O modules and modern control execution environments. This translation layer allows the modern control system to communicate with existing legacy hardware without requiring physical rewiring or hardware modification, enabling upgrade while maintaining system operational continuity.
Solution Approach 2:
The patent implements preliminary configuration of the modern control execution environment to match the legacy system's I/O architecture before migration begins. By pre-configuring communication paths and translation mechanisms, the system prepares the modern control environment to seamlessly interface with existing hardware, eliminating the need for hardware alteration or system shutdown during the actual migration process.
3Adaptability or versatility
If control strategies are migrated from legacy to modern control systems, then access to modern I/O functions is improved, but hardware complexity and rewiring requirements increase
Solution Approach 1:
The patent creates a universal communication interface that allows the modern control execution environment to access diverse I/O functions through a standardized translation layer. This universal interface can communicate with various legacy I/O modules without requiring dedicated hardware pathways for each function, reducing hardware complexity while maintaining access to modern I/O capabilities.
Data Source
AI summary
A method comprises controlling, via a first process of a process controller, the industrial process, wherein the process controller is coupled, via a communication path, to an input/output (I/O) link execution environment manager (IOL EE), the process controller comprising a microprocessor configured to host a first control execution environment to support a first set of I/O functions and corresponding control execution functions to control the industrial process; migrating a subset of the first set of I/O functions and corresponding control execution functions to a second process of the process controller to form a second set of I/O functions and corresponding control functions, wherein the microprocessor is configured to host a second control execution environment to support the second set of I/O functions and the corresponding control execution functions to control the industrial process; and controlling, via second process.