Virtual Automation Device Load Distribution for Real-Time Control
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Solution Overview
Problem
In automation technology, mixed configurations of real and virtual automation components face challenges in maintaining real-time behavior, leading to potential disruptions and errors due to decoupled real-time behavior in simulations, which hinders trouble-free commissioning and operation.
Innovation Solution
The method involves distributing virtual controllers across servers, monitoring and managing computing load to ensure real-time capability by outsourcing virtual automation devices to additional servers when utilization thresholds are reached, using system functions to configure and parameterize process objects for process control, communication, and monitoring, thereby maintaining deterministic behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If virtual automation devices are used for simulation and commissioning, then commissioning can be performed before real devices are available, but real-time behavior cannot be guaranteed leading to disruptions and errors
Solution Approach 1:
The system dynamically adjusts the distribution of virtual automation devices across multiple servers based on real-time load conditions. When a server's utilization reaches a threshold, virtual devices are automatically migrated to other servers, ensuring that real-time behavior requirements are maintained while enabling continuous commissioning work
Solution Approach 2:
The system segments virtual automation devices and distributes them across multiple servers rather than concentrating them on a single server. This segmentation allows each server to manage a manageable load while maintaining overall system real-time performance, resolving the contradiction between commissioning capability and real-time reliability
2Productivity
If computing load increases on a server, then more virtual automation devices can be hosted, but real-time behavior is violated when utilization exceeds threshold
Solution Approach 1:
The system continuously monitors server utilization and implements feedback control by automatically migrating virtual automation devices when utilization thresholds are reached. This feedback mechanism ensures that real-time capability is maintained while maximizing the hosting capacity of the server infrastructure
Solution Approach 2:
The distribution of virtual automation devices is made dynamic rather than static, allowing the system to adapt to changing load conditions. Virtual devices are automatically redistributed based on real-time server utilization, enabling the system to maintain real-time performance while hosting the maximum possible number of virtual devices
Data Source
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AI summary
The invention relates to a method for operating an automation device (1) comprising at least one real automation device (2) for controlling a technical process, an operator station for operating and monitoring the technical process to be controlled, an engineering system (6), and virtual automation devices (12 to 14), each of which replicates functions of a real automation device and is stored on a server (10). In particular, the commissioning of the automation device (1) is simplified by suitable measures, whereby the real-time behavior of the automation device (1) is largely ensured by a suitable distribution of the virtual controllers or virtual automation devices (12 to 14) on servers (10, 22).