Virtualized I/O Architecture for Real-Time Industrial Process Control
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Solution Overview
Problem
Current industrial control systems face limitations in scalability, reconfigurability, reliability, availability, and performance due to hardware-centric architectures, limited memory and bandwidth, and inefficient data management, which hinder effective process control and simulation.
Innovation Solution
A multi-purpose dynamic simulation and control platform (MPDSC) decouples hardware from software, enabling virtual and physical components to cooperate for dynamic simulation and run-time process control, using an I/O Switch to abstract I/O data delivery and support seamless interactions between virtual and physical nodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware-centric architecture is used for industrial 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 control components through virtualization technology. Virtual controllers, virtual I/O devices, and virtual network devices replicate the functionality of their physical counterparts, enabling multiple virtual instances to coexist on shared hardware. This copying approach allows the system to be reconfigured by creating, deleting, or migrating virtual instances without physical hardware changes, thus improving reconfigurability while avoiding the complexity of managing additional physical hardware.
Solution Approach 2:
The patent replaces the traditional mechanical/hardware-based control system architecture with a software-defined virtualized architecture. Instead of physically reconfiguring control systems by adding or removing hardware components, the system uses virtualization software to dynamically allocate and reconfigure control functions. This substitution of hardware mechanisms with software-based virtualization enables flexible reconfiguration while reducing hardware complexity.
2Productivity
If more physical hardware components are added to improve system performance, then processing capability increases, but system complexity and cost increase
Solution Approach 1:
The patent consolidates multiple physical hardware resources into shared infrastructure through virtualization. Multiple virtual controllers, virtual I/O devices, and processing functions are merged onto shared physical servers, storage systems, and network devices. This merging approach increases processing capability by utilizing the combined power of shared hardware resources while reducing system complexity by eliminating redundant physical components and simplifying the overall architecture.
Solution Approach 2:
The patent creates universal virtualized hardware platforms that can perform multiple control functions simultaneously. A single physical server can host multiple virtual controllers serving different control applications, and virtual I/O devices can be dynamically allocated to different virtual machines as needed. This multi-functionality approach enhances processing capability for diverse control tasks while reducing system complexity by replacing specialized hardware with versatile virtualized platforms.
3Speed
If data is managed in centralized databases, then data consistency is maintained, but data access efficiency and real-time performance deteriorate
Solution Approach 1:
The patent segments the centralized database architecture into distributed data storage and management across multiple virtualized components. Data is divided and stored across virtual file systems, virtual databases, and distributed storage resources associated with different virtual machines. This segmentation enables parallel data access from multiple virtual controllers simultaneously, improving data access speed while maintaining data consistency through virtualized data management protocols and coordination mechanisms.
4Ease of operation
If simulation and control functions are separated, then functional clarity is improved, but system integration complexity increases
Solution Approach 1:
The patent introduces a virtualization layer as an intermediary between simulation functions and control functions. Virtual controllers serve as mediators that can operate in simulation mode or real-time control mode, seamlessly bridging the gap between simulation environments and actual process control. This intermediary approach maintains functional clarity by keeping simulation and control logic separate in different virtual instances, while reducing integration complexity by providing standardized virtual interfaces and communication protocols that simplify connectivity between components.
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.