Virtualized I/O Switching for Reconfigurable Process Control Nodes
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Solution Overview
Problem
Current industrial control systems face limitations in scalability, reconfigurability, reliability, and performance due to hardware-driven architectures, which restrict their ability to efficiently manage data and I/O operations, leading to issues with data archiving, communication resource utilization, and system resilience.
Innovation Solution
A multi-purpose hardware/software architecture decouples hardware from software, enabling dynamic simulation and run-time process control through a virtualized environment that abstracts I/O operations, allowing for easier scaling, reconfiguration, and improved reliability and availability by using virtual and physical components that cooperate within the MPDSC platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware-driven architecture is used in industrial control systems, then system stability and reliability are maintained, but scalability and reconfigurability are limited
Solution Approach 1:
The system segments control functions into virtual machines that can be independently deployed and managed. Each virtual machine encapsulates specific control logic and can be scaled or reconfigured without affecting the physical hardware architecture, thereby improving scalability while maintaining system stability.
Solution Approach 2:
The patent implements a universal virtualization layer that allows a single physical control system to host multiple virtual machines with different control functions. This multi-functionality enables the system to adapt to various process control scenarios without requiring dedicated hardware for each function, enhancing reconfigurability while reducing hardware complexity.
2Reliability
If centralized hardware devices are deployed for process control, then system reliability is improved, but system downtime for maintenance and upgrades increases
Solution Approach 1:
The patent extracts control software from physical hardware and places it in virtual machines that can be independently updated and maintained. This separation allows maintenance and upgrades to be performed on virtual instances without taking the underlying physical hardware offline, reducing maintenance downtime while maintaining system availability.
Solution Approach 2:
The system enables preliminary testing and validation of control logic in virtual environments before deploying to production hardware. Updates can be prepared and tested in isolated virtual machines, then activated without interrupting ongoing control operations, thereby maintaining high system availability during maintenance activities.
3Productivity
If virtualized components are used for process control, then system elasticity and responsiveness are enhanced, but data management complexity increases
Solution Approach 1:
The patent introduces a virtualization management layer that acts as an intermediary between virtual machines and physical data resources. This layer abstracts and manages data flow, storage, and access protocols, simplifying data management for virtualized components while enabling high-speed data processing and system responsiveness.
4Adaptability or versatility
If hardware-bound control systems are used, then implementation simplicity is maintained, but system resilience and flexibility are reduced
Solution Approach 1:
The patent adds a virtualization dimension to traditional hardware-bound control systems. By layering virtual machines above physical hardware, the system gains flexibility and adaptability in the virtual space while maintaining the simplicity and reliability of the underlying hardware architecture, thus achieving both goals simultaneously.
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.