Virtual I/O Control for Open Process System Simulation
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Solution Overview
Problem
Open process control systems face challenges in implementing a simulation function without specialized controllers, as they require I/O connection devices and general-purpose controllers to be prepared, and there is a need for compatibility with multiple vendors and networks to prevent inconsistencies.
Innovation Solution
A control device with a communication unit, acquisition unit, and calculation unit that communicates with I/O connection devices and information processing devices via a network, allowing for the acquisition of device information and execution of control calculations, even when some actual equipment is not prepared, and enabling the simulation function to be implemented across a general-purpose network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a general purpose controller is used instead of a specialized controller in an open process control system, then system cost is reduced and compatibility with multiple vendors is improved, but the ability to perform simulation functions is worsened because simulation requires actual I/O connection devices and equipment to be prepared
Solution Approach 1:
The patent creates a virtual copy of the I/O connection device that replicates the device information and communication interface of actual physical equipment. This virtual I/O connection device allows simulation operations to be performed without requiring actual hardware, enabling the control device to execute control calculations and test control logic in a virtual environment that mimics the real system architecture.
Solution Approach 2:
The patent introduces a virtual I/O connection device as an intermediary layer between the control device and the actual physical equipment. This intermediary enables communication and data exchange without requiring the physical equipment to be present, allowing simulation functions to operate independently while maintaining compatibility with the open process control system architecture.
2Productivity
If simulation is performed without actual I/O connection devices prepared, then hardware dependency is reduced and operation testing becomes possible earlier, but inconsistency may occur in multivendor environments where device information must be disclosed across different vendors' equipment
Solution Approach 1:
The patent creates a universal virtual I/O connection device that can represent multiple different vendors' actual equipment through a standardized interface. The virtual device discloses device information in a consistent format that works across multivendor environments, allowing the control device to perform simulation operations reliably without requiring vendor-specific hardware or configuration.
3Adaptability or versatility
If device information is disclosed across the network in an open process control system, then multivendor compatibility is improved and simulation becomes possible, but system complexity increases due to the need for network communication and information management between control device and I/O connection devices
Solution Approach 1:
The patent extracts the essential device information from actual physical I/O connection devices and consolidates it into a virtual I/O connection device. This extraction eliminates the need for complex network communication infrastructure with multiple actual devices, reducing system complexity while maintaining multivendor compatibility through the simplified virtual device interface.
Data Source
AI summary
A control device includes a communication unit, an acquisition unit, and a calculation unit. The communication unit performs communication with an I/O connection device where an I/O device is connected and an information processing device, via a network. The acquisition unit acquires device information related to the I/O device from at least one of a first storage unit included in the I/O connection device and storing the device information and a second storage unit included in the information processing device and storing the device information. The calculation unit performs control calculation related to the I/O device by using the device information.