Virtual Processor for Unobtrusive Legacy System Analytics
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Solution Overview
Problem
Conventional methods for detecting machine faults in industrial and healthcare assets are inadequate, as they fail to detect intermittent damage and require cumbersome, labor-intensive troubleshooting processes, often only identifying issues after complete failure and lacking real-time monitoring capabilities.
Innovation Solution
A system that enables unobtrusive observation and analytics of legacy systems using a virtual processor, allowing for in-situ monitoring and data capture without modifying existing software, leveraging existing hardware capabilities and emulating older hardware in software to provide real-time monitoring and analytics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional troubleshooting methods are used with probes and extensions, then fault detection is possible, but the process is cumbersome, time-consuming, and labor-intensive
Solution Approach 1:
The patent creates a virtual copy of the legacy processor that replicates its instruction set architecture and operational behavior. This virtual processor runs alongside the original system, capturing and analyzing processor states without physical intervention. The virtual model mirrors the legacy system's functionality, enabling remote observation and diagnostics eliminating the need for physical probe attachment and manual log inspection
Solution Approach 2:
The patent introduces a virtual machine monitor and analytics engine as intermediary software layers between the legacy processor and the analysis system. These intermediaries capture processor states, memory contents, and execution flows without requiring physical access to the asset. The intermediary software translates legacy processor operations into analyzable data formats, enabling remote fault detection and eliminating manual troubleshooting steps
2Loss of information
If probes and extensions are attached to the asset, then fault data can be read, but the asset operation is interrupted and maintenance is labor-intensive
Solution Approach 1:
The virtual processor creates a digital replica of the legacy system's processor state, memory, and execution environment. This copy enables complete observation of fault logs, register states, and program counters without physical attachment. The virtual model provides the same diagnostic information as physical probes would, but accessible remotely through software interfaces, dramatically improving maintenance convenience
Solution Approach 2:
The patent replaces the mechanical/physical troubleshooting system (probes, extensions, manual log reading) with a software-based virtualization system. Instead of physically attaching devices to read fault logs, the system uses virtual machine monitors and analytics engines to capture and analyze processor states programmatically. This substitution eliminates manual intervention and physical access requirements, making maintenance remote and convenient
3Adaptability or versatility
If legacy hardware is emulated in software, then backward compatibility is achieved, but system complexity increases
Solution Approach 1:
The virtual processor architecture is designed to be universal, supporting multiple legacy processor types through configurable instruction set implementations. The same virtualization infrastructure can emulate different processor architectures, making the system adaptable to various legacy assets. This multi-functionality achieves backward compatibility across different hardware platforms while managing complexity through a unified software approach
Solution Approach 2:
The patent implements backward compatibility by changing software parameters and configuration settings rather than requiring different hardware systems. The virtual processor can be configured with different instruction set architectures, memory models, and operational parameters to match various legacy systems. This parameter-based adaptation allows a single software platform to support multiple legacy hardware types, achieving versatility without proportionally increasing complexity
Data Source
AI summary
The example embodiments are directed to a system and method for a virtual processor that enables unobtrusive observation of legacy systems for analytics in a system-on-chip (SoC) environment. In one example, the method includes implementing a virtual processor in field programmable gate array (FPGA) programmable logic, the virtual processor comprising a virtual version of a target system, capturing one or more operational parameters in volatile memory of the virtual processor using an access controller configured to provide direct access to the volatile memory of the virtual processor, streaming the one or more operational parameters to the embedded processor, storing the one or more operational parameters in volatile memory of the embedded processor, and performing in-situ monitoring using the one or more operational parameters.