Virtualized Real-Time I/O Switching for Reconfigurable Process Control
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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 responsiveness.
Innovation Solution
A multi-purpose hardware/software architecture, referred to as the MPDSC platform, decouples hardware from software, enabling dynamic simulation and run-time process control by virtualizing I/O operations through an I/O Switch that abstracts I/O data delivery between virtual and physical nodes, using publish/subscribe layers and a virtual communication network.
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 patent creates virtual copies of physical I/O components through virtualization. Virtual I/O components are software representations that replicate the functionality of physical hardware, allowing multiple virtual instances to be created from a single physical component. This enables scalable system expansion without proportional hardware increases and allows flexible reconfiguration by modifying virtual component assignments rather than physical hardware connections.
Solution Approach 2:
The patent introduces a virtualization layer as an intermediary between physical hardware and control software. This intermediate virtualization layer decouples the hardware from software, allowing the physical I/O components to remain stable and reliable while the virtual layer provides scalability and reconfigurability. The virtualization layer acts as a mediator that translates between physical hardware operations and virtual component operations.
2Adaptability or versatility
If virtualization is implemented to improve scalability and reconfigurability, then hardware dependencies are reduced, but system complexity increases
Solution Approach 1:
The patent creates a universal virtualization layer that can manage multiple types of I/O components through a common interface and framework. The virtual I/O component architecture provides multi-functional capabilities, allowing the same virtualization infrastructure to handle diverse physical devices (analog, digital, communication interfaces) through standardized virtual representations. This universality reduces the need for device-specific complexity while maintaining reconfigurability.
3Productivity
If traditional hardware-driven I/O management is used, then system reliability is maintained, but data management efficiency and responsiveness deteriorate
Solution Approach 1:
The patent creates virtual copies of physical I/O components that can be managed more efficiently than physical hardware. The virtual I/O components allow for flexible data routing, virtualization of I/O resources, and improved data management through software-based control. This copying approach enables efficient data management while maintaining reliability through the underlying physical hardware stability.
Solution Approach 2:
The patent introduces dynamic capabilities to I/O management through virtualization. The virtual I/O component architecture allows for dynamic allocation, assignment, and reconfiguration of I/O resources without physical hardware changes. This dynamics enables responsive data management where resource allocation can be adjusted in real-time based on system needs, improving productivity while the underlying physical hardware maintains reliability.
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.