Virtualized real-time I/O in process control systems
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.
1. A method of controlling an industrial process, the method comprising:
switching, by an input/output (I/O) router communicatively coupled to a plurality of field devices and to a plurality of nodes, I/O data between the plurality of field devices and the plurality of nodes, the switching based on a set of records stored at the I/O router,
the plurality of nodes including at least one process controller,
the switching based on a first subscription of the I/O router to a publication of first I/O data indicative of information generated by a field device of the plurality of field devices and based on a second subscription of the I/O router to a publication of second I/O data indicative of a control signal generated by a node included in the plurality of nodes, and
the switching thereby controlling at least a portion of the industrial process.
2. The method of claim 1 , wherein the switching includes:
obtaining, by the I/O router and based on the second subscription, the publication of the second I/O data; and
publishing, by the I/O router, third I/O data indicative of the second I/O data, the publishing based on an indication, included in the set of records, of at least one node that is a recipient of the third I/O data and that corresponds to the field device or to another field device, of the plurality of field devices, that operates in response to the control signal to thereby control the at least the portion of the industrial process.
3. The method of claim 2 , wherein the switching further includes:
obtaining, by the I/O router and based on the first subscription to the publication of the first I/O data, the publication of the first I/O data; and
publishing, by the I/O router, fourth I/O data indicative of the first I/O data, the publishing of the fourth I/O data based on an indication, included in the set of records, of the node or another node, of the plurality of the nodes, that is a recipient of the information generated by the field device.
4. The method of claim 3 , wherein the node or the another node is a process controller or another controller.
5. The method of claim 1 , wherein:
the set of records indicate a set of sending nodes that publish respective information and a set of recipient nodes that are respective receivers of the respective information, the set of sending nodes including at least a first portion of the plurality of nodes and at least a first portion of the plurality of field devices, and the set of receiving nodes including at least a second portion of the plurality of nodes and at least a second portion of the plurality of field devices; and
the method further comprises switching, by the I/O router, the respective information between the set of sending nodes and the set of receiving nodes based on the set of records.
6. The method of claim 5 , wherein at least one of:
the set of sending nodes includes a first at least one physical node excluded from the plurality of field devices and a first at least one virtual node excluded from the plurality of nodes; and
the set of recipient nodes includes a second at least one physical node excluded from the plurality of field devices and a second at least one virtual node excluded from the plurality of nodes.
7. The method of claim 5 , wherein the switching of the respective information between the set of sending nodes and the set of receiving nodes includes:
obtaining, by the I/O router via first respective publications of the set of sending nodes, respective portions of the respective information; and
publishing, by the I/O router, second respective publications indicative of the respective portions of the respective information.
8. The method of claim 7 , wherein the obtaining of the respective portions of the respective information via the first respective publications and the publishing of the second respective publications indicative of the respective portions of the respective information are based on a packet protocol.
9. The method of claim 5 , wherein the switching of the respective information between the set of sending nodes and the set of receiving nodes is based on unique identifiers of the set of sending nodes and the set of receiving nodes, the unique identifiers based on a configuration database associated with the industrial process and indicated in the set of records.
10. The method of claim 9 , wherein the switching of the respective information is further based on unique identifiers of different portions of the respective information, the unique identifiers of the different portions of the respective information indicated in the set of records.
11. The method of claim 5 , further comprising updating, by the I/O router, the set of records based on at least one of: a request of at least one node of the plurality of nodes to subscribe to specific information, a change to an existing subscription, or a change to an existing publication.
12. An input/output (I/O) router communicatively coupling a plurality of field devices and a plurality of nodes, the I/O router comprising:
one or more memories storing a set of records indicating sending nodes that publish various I/O data and recipient nodes that are respective receivers of the various I/O data, and
computer-executable instructions stored on the one or more memories and executable by one or more processors of the I/O router to, based on the set of records, switch the various I/O data between the plurality of field devices and the plurality of nodes,
the plurality of nodes including at least one process controller,
the switching of the various I/O data being based on the I/O router being a subscriber to a first publication of first I/O data indicative of data generated by a field device of the plurality of field devices and based on the I/O router being a subscriber to a second publication of second I/O data indicative of a control signal generated by a node included in the plurality of nodes, and
the switching of the various I/O data thereby controlling at least a portion of an industrial process.
13. The I/O router of claim 12 , wherein:
the I/O router is a publisher of third I/O data indicative of the first I/O data; and
the set of records indicates that a first node is a subscriber to a publication of the third I/O data, the first node corresponding to the node or to another node, of the plurality of nodes, that generates a respective control signal in response to the data generated by the field device to thereby control the at least the portion of the industrial process.
14. The I/O router of claim 13 , wherein:
the I/O router is a publisher of fourth I/O data indicative of the second I/O data; and
the set of records indicates that a second node is a subscriber to a publication of the fourth I/O data, the second node corresponding to the field device or to another field device, of the plurality of field devices, that operates in response to the respective control signal to thereby control the at least the portion of the industrial process.
15. The I/O router of claim 14 , wherein the second node is an intervening node or device communicatively coupled to the I/O router and to the field device or the another field device.
16. The I/O router of claim 12 , wherein:
the set of records indicates a set of sending nodes, each of which publishes respective information, and a set of recipient nodes that respectively receive the publications of the respective information, the set of sending nodes including at least a first portion of the plurality of nodes and at least a first portion of the plurality of field devices, and the set of recipient nodes including at least a second portion of the plurality of nodes and at least a second portion of the plurality of field devices; and
the computer-executable instructions are further executable by the one or more processors to cause the I/O router to switch the respective information between the set of sending nodes and the set of receiving nodes based on the set of records.
17. The I/O router of claim 16 ,
wherein at least one of:
the set of sending nodes includes a first at least one physical node other than the field device and a first at least one virtual node; and
the set of recipient nodes includes a second at least one physical node other than the field device and a second at least one virtual node; and
wherein the first at least one virtual node and the second at least one virtual node exclude any virtual process controllers.
18. The I/O router of claim 16 , wherein the set of sending nodes publishes the respective information by utilizing a packet protocol, and the set of receiving nodes receives the publications of the respective information via the packet protocol.
19. The I/O router of claim 12 , wherein the set of records stores indications of unique identifiers of each node included in the plurality of nodes, of each field device included in the plurality of field devices, and of the various I/O data, and wherein the switching is based on the unique identifiers.
20. The I/O router of claim 12 , wherein the computer-executable instructions are further executable by the one or more processors to cause the I/O router to update the set of records based on at least one of: a request of at least one node of the plurality of nodes to subscribe to specific information, a change to an existing subscription, or a change to an existing publication.