Software-Defined Process Control With Dynamic Resource Reallocation
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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, dynamically managing resources through a hyper-converged infrastructure to support dynamic demands during runtime.
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 applies universality by using general-purpose computing hardware (standard servers, storage devices, and networking equipment) to perform multiple process control functions. Instead of dedicated hardware for each control function, the system uses virtualization to run multiple virtual machines on common hardware platforms, making the hardware versatile and reducing overall system complexity while maintaining reliability through software-based control.
Solution Approach 2:
The patent employs copying by creating virtual copies of control systems through virtual machines. Multiple identical or customized control environments can be replicated on the same physical hardware, allowing for redundancy, testing, and scaling without requiring additional purpose-built hardware for each instance, thereby reducing device complexity while preserving system reliability.
2Adaptability or versatility
If purpose-built hardware is used in traditional process control systems, then initial engineering costs are increased, but adaptability is improved
Solution Approach 1:
The patent applies dynamics by implementing a flexible, software-defined control architecture where control functions can be dynamically allocated, modified, and scaled through virtual machines. This allows the system to adapt to changing process requirements without requiring new hardware engineering, reducing initial costs while maintaining high adaptability through software-based reconfiguration.
Solution Approach 2:
By using universal hardware platforms that can run multiple virtual control systems, the patent reduces initial engineering costs while maintaining adaptability. The same hardware infrastructure can support different control applications and be reconfigured as needed, eliminating the need for custom-built hardware for each application.
3Stability of the object's composition
If hardware-centric architecture is used, then system stability is improved, but ease of operation and maintenance are worsened
Solution Approach 1:
The patent replaces the mechanical/hardware-centric control architecture with a software-based virtualized system. Instead of relying on fixed hardware configurations, control functions are implemented as virtual machines that can be easily deployed, moved, and managed through software, improving ease of operation and maintenance while maintaining system stability through virtualization overhead and abstraction layers.
4Reliability
If dedicated hardware resources are allocated to each control function, then reliability is improved, but resource utilization efficiency is worsened
Solution Approach 1:
The patent merges multiple dedicated hardware resources into shared physical infrastructure that hosts multiple virtual machines. By consolidating control functions onto common hardware platforms through virtualization, the system maintains the isolation and reliability of dedicated resources while achieving high resource utilization efficiency through shared hardware assets serving multiple control functions simultaneously.
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.