Virtualized Industrial Control Architecture for Real-Time Simulation

The system is segmented into distinct virtualization layers (infrastructure layer, virtualization layer, application layer) that can be independently configured and managed. This allows the control system to be reconfigured by modifying virtual components without changing the underlying hardware architecture, thereby improving reconfigurability while maintaining manageable complexity through modular design.

The patent implements dynamic virtualization where virtual devices and control modules can be dynamically created, moved, and configured at runtime. The virtualization layer enables flexible allocation of computational resources and dynamic reconfiguration of control logic without physical hardware changes, enhancing adaptability while the virtualized abstraction manages complexity.

The virtualization layer provides universal abstractions that can represent multiple physical devices and configurations through single virtual instances. Virtual devices can be replicated and distributed across different physical platforms, enabling scalable system expansion without proportionally increasing management complexity, as the same virtualization mechanisms apply regardless of system size.

The patent introduces a virtualization layer as an intermediary between the physical infrastructure and control applications. This intermediary abstracts the complexity of hardware management and provides standardized interfaces for scalability, allowing systems to grow by adding virtualized resources without directly increasing the complexity visible to end users or applications.

Data management is segmented between edge devices (controllers, gateways) and centralized cloud infrastructure. Controllers store and process only essential local data, while historical archiving and extensive data analysis are performed in the cloud. This segmentation reduces controller memory usage and communication overhead while maintaining simplified data management through automated cloud-based handling of large-scale data operations.

The patent extracts data archiving and heavy computational tasks from the controller environment and places them in cloud-based data lakes. This extraction removes the burden of large-scale data storage from controllers, freeing up memory and communication resources while centralized cloud systems handle data management operations, achieving both reduced local resource usage and simplified overall data management.

The patent creates virtual copies of physical control components that can be used for simulation, testing, and reconfiguration without affecting the actual physical system. These virtual replicas maintain the functional behavior of physical devices, enabling dynamic simulation and what-if analysis while the physical components continue to provide reliable run-time control. The virtual copies can be modified and reconfigured freely without compromising physical system reliability.

The system implements dynamic switching between virtual and physical operational modes. During normal operation, physical components provide reliable control, while virtual components enable simultaneous simulation and testing. The virtualization layer allows dynamic reconfiguration of control logic in the virtual environment, and validated changes can be safely deployed to physical systems, thereby enhancing simulation capability while maintaining reliability through controlled transition protocols.