Virtual and Physical Backplane Bridge for Modular Control Systems

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Solution Overview

Problem

Industrial control systems face complexity and increased costs due to the need for interconnectivity between various control modules and racks, leading to higher lead times and expenses for manufacturers, while also requiring flexibility to incorporate modules from different vendors without proprietary dependencies.

Innovation Solution

A system and method that bridges physical and virtual backplanes, allowing seamless communication and interaction between physical and virtual control and communication modules without specific configuration or programming, using a backplane bridge component, overlay component, virtual backplane interface, physical backplane interface, and storage component to create a unified system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If control systems use modular architecture with multiple racks and modules, then functionality and granularity are improved, but system complexity and hardware size increase

Engineering Contradiction:

Improvefunctionality granularityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system divides control functionality into separate modules that can be independently selected and configured. Modules are organized into racks and backplanes, allowing customers to purchase only the specific modules needed for their application rather than requiring complete control systems from a single vendor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The backplane serves as a universal interface that can accommodate different types of control modules from various vendors. The standardized backplane design enables multiple module types to be integrated into a single system, providing multi-vendor compatibility and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If control systems incorporate modules from different vendors, then flexibility and cost are improved, but integration complexity increases

Engineering Contradiction:

Improvemulti-vendor flexibilityVSAvoidintegration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The backplane is designed as a universal interface that accepts modules from different vendors through standardized connection protocols. This allows customers to mix and match modules from multiple vendors without requiring complex custom integration work for each vendor combination.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The backplane acts as an intermediary layer between control modules from different vendors, providing standardized mechanical, electrical, and communication interfaces that mediate between disparate module designs and enable seamless integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If control systems require all hardware to be purchased before testing, then system reliability is improved, but lead time and expense increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidlead time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system allows customers to purchase and test individual modules or small groups of modules separately rather than requiring complete system procurement. This modular purchasing approach enables phased testing and validation, reducing the time and cost of getting started while maintaining system reliability through proper module selection.

Inventive Principle:

Principle #1Segmentation

4Reliability

If control systems use proprietary hardware, then system reliability is improved, but adaptability and cost are reduced

Engineering Contradiction:

Improvesystem reliabilityVSAvoidhardware adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The backplane provides a universal platform that maintains system reliability through standardized interfaces while enabling adaptability to modules from multiple vendors. This universal design allows the system to achieve both reliability through proven module designs and adaptability through multi-vendor compatibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8250279B2Constituting a control system with virtual and physical backplanes and modules as building blocks

Publication Date: 2012.08.21 ROCKWELL AUTOMATION TECH INC

AI summary

A custom control system created based on combinations of software applications and hardware control and communication modules overlaid in a virtual backplane. The user can select the modules of interest and map them together without the loss of communications between the modules while the control system is configured and overlaid. The user can then archive the system design and implement the system with a greater level of confidence in the ability of the design to meet the requirements of the application while reducing the costs of the implementation.