Software-Defined Process Control With Dynamic Resource Allocation
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Solution Overview
Problem
Current industrial process control systems are inflexible and hardware-centric, leading to increased costs and complexity in 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 through a hyper-converged infrastructure, including a software-defined networking layer, application layer, and storage layer, to support dynamic demands and conditions in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purpose-built hardware is used in traditional process control systems, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses virtualization to create virtual copies of control functions and hardware resources. Virtual machines and containers replicate control logic and I/O handling capabilities, allowing multiple virtual controllers to share physical hardware infrastructure, thereby reducing overall system complexity while maintaining reliability through redundancy
Solution Approach 2:
The patent implements a universal hardware platform that can perform multiple control functions through software configuration. A single physical server can host multiple virtual controllers, I/O servers, and database services, replacing the need for dedicated purpose-built hardware for each function and reducing device complexity
2Stability of the object's composition
If purpose-built hardware is used in traditional process control systems, then system stability is improved, but adaptability deteriorates
Solution Approach 1:
The patent implements dynamic resource allocation where virtualized control functions can be migrated, scaled, and reconfigured in real-time based on changing process requirements. The orchestrator dynamically manages resource distribution across the infrastructure, allowing the system to adapt to new control algorithms, additional I/O devices, or changing process conditions without hardware changes
Solution Approach 2:
Virtualization enables rapid copying and replication of control functions across multiple virtual instances. Control logic can be duplicated across virtual machines for load distribution or failover scenarios, providing both stability through redundancy and adaptability through easy deployment of additional instances
3Ease of operation
If traditional hardware-centric architecture is used, then ease of operation is maintained, but productivity deteriorates due to manual configuration and deployment
Solution Approach 1:
The patent implements self-service automation through the orchestrator that automatically provisions, configures, and manages virtualized control functions. The system self-manages resource allocation, monitors system state, and performs automated deployment of control algorithms, eliminating manual configuration tasks and significantly improving engineering productivity while maintaining ease of operation through standardized interfaces
4Measurement precision
If dedicated I/O devices are used for each field device protocol, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple protocol-specific I/O device functions into a single virtualized I/O server running on the software-defined infrastructure. The I/O server consolidates support for HART, Fieldbus, Profibus, and other protocols into one unified software component, reducing the number of physical I/O devices needed while maintaining precise protocol-specific communication capabilities through software configuration
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.). Thus, dynamic (re-)allocation of hardware/software resources is primarily, if not entirely, and continually governed in real-time by present requirements and needs of application layer services as well as dynamically changing SDCS conditions.