Virtual Machine Link for DCS Message Translation in Process Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems face challenges in communicating effectively between models trained to control manufacturing processes and distributed control systems (DCSs) due to security restrictions and protocol differences, which impedes the implementation of optimized control strategies.
Innovation Solution
The implementation of a virtual machine system that includes a controller server and client, allowing for the transformation of messages between different formats, enabling communication between the model and the DCS, and facilitating the execution of control actions based on operational states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a virtual machine system with message transformation is implemented to enable communication between models and DCSs, then communication compatibility and integration capability are improved, but device complexity increases
Solution Approach 1:
The virtual machine acts as an intermediary system between the control model and the DCS. It receives messages from the DCS in the first message format, transforms them into the second message format required by the model, processes the data through the control model, and then transforms the response messages back to the DCS format. This mediator approach enables communication between incompatible systems without requiring changes to the existing DCS or model architectures.
2Adaptability or versatility
If message format transformation is performed to enable communication between different systems, then interoperability is improved, but processing time and computational overhead increase
Solution Approach 1:
The virtual machine is pre-configured with knowledge of both the first message format (DCS protocol) and the second message format (model protocol). Message transformation rules, data mapping relationships, and protocol specifications are established in advance. When messages are transmitted, the virtual machine can perform rapid format conversion using pre-compiled transformation logic, significantly reducing processing time compared to dynamic format conversion.
Data Source
AI summary
Systems and methods are provided for use in communicating with a distributed control system (DCS) associated with a manufacturing plant. One example system includes a virtual machine hosted in a computing device and coupled to the DCS via a network connection, where the virtual machine includes a controller server and a controller client. The controller server includes a controller specific to a process of the plant, and the controller client is configured to host communication between the controller server in the virtual machine and the DCS of the plant. The controller client, then, is further configured to receive a message from the DCS, via the network connection, transform the message into a JSON message, and communicate the JSON message to the controller server.