Virtual I/O Switching for Seamless Process Control Node Switchover
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Solution Overview
Problem
Current industrial control systems face limitations in scalability, reconfigurability, reliability, and performance due to hardware-driven architectures, which restrict their ability to efficiently manage data and I/O operations, leading to issues with data archiving, communication resource utilization, and system resilience.
Innovation Solution
A multi-purpose hardware/software architecture decouples hardware from software, enabling dynamic simulation and run-time process control through a virtualized environment that abstracts I/O operations, allowing for seamless scaling, reconfiguration, and improved reliability and availability by using virtual and physical components that cooperate in process control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware-driven architecture is used in process control systems, then system stability and reliability are maintained, but scalability and reconfigurability are limited
Solution Approach 1:
The patent creates virtual copies of physical I/O components and control system elements. Virtual I/O servers replicate the functionality of physical I/O modules, allowing multiple virtual instances to operate simultaneously. This enables scalable system expansion without adding proportional physical hardware, as virtual components can be instantiated and configured software-defined.
Solution Approach 2:
The patent introduces a virtualization layer that adds a software dimension between physical hardware and control applications. This dimensional addition allows the system to manage both physical and virtual components in the same architectural space, enabling flexible reconfiguration through software while maintaining physical hardware stability.
2Adaptability or versatility
If virtualized components are used to improve scalability and reconfigurability, then system flexibility increases, but system complexity increases
Solution Approach 1:
The virtual I/O server is designed as a universal platform that can manage multiple types of I/O operations through a single unified interface. It handles diverse I/O protocols and device types through virtualization, allowing the same virtual infrastructure to support various control functions without requiring separate specialized hardware for each function type.
Solution Approach 2:
The virtual I/O server acts as an intermediary layer between physical I/O devices and control applications. It mediates all I/O operations by translating between physical device protocols and virtualized interfaces, simplifying the complexity for end applications while managing the underlying hardware diversity centrally.
3Reliability
If physical components are used for process control, then system reliability is maintained, but downtime during maintenance and upgrades increases
Solution Approach 1:
The system performs preliminary actions by maintaining virtual replicas of I/O components that can operate independently of physical hardware status. Before physical maintenance or upgrades, the virtualized environment is already configured and ready to take over, allowing seamless transitions without interrupting control functions.
Solution Approach 2:
Virtual copies of physical I/O components enable hot-swapping capabilities. When physical hardware requires maintenance, the virtualized instance continues to handle I/O operations, and the physical component can be replaced without system shutdown. The virtual copy ensures continuity of control functions during hardware maintenance.
4Ease of operation
If data is archived in centralized databases, then data management is simplified, but communication resource utilization and system performance deteriorate
Solution Approach 1:
The patent segments data management by distributing data storage and processing across multiple virtual I/O server instances rather than consolidating everything in a single centralized database. Each virtual I/O server manages its own data locally, reducing communication overhead and allowing parallel data operations without bottlenecking through a single centralized access point.
Data Source
AI summary
A Multi-Purpose Dynamic Simulation and run-time Control platform includes a virtual process environment coupled to a physical process environment, where components/nodes of the virtual and physical process environments cooperate to dynamically perform run-time process control of an industrial process plant and/or simulations thereof. Virtual components may include virtual run-time nodes and/or simulated nodes. The MPDSC includes an I/O Switch which delivers I/O data between virtual and/or physical nodes, e.g., by using publish/subscribe mechanisms, thereby virtualizing physical I/O process data delivery. Nodes serviced by the I/O Switch may include respective component behavior modules that are unaware as to whether or not they are being utilized on a virtual or physical node. Simulations may be performed in real-time and even in conjunction with run-time operations of the plant, and/or simulations may be manipulated as desired (speed, values, administration, etc.). The platform simultaneously supports simulation and run-time operations and interactions/intersections therebetween.