Süeda Asil
Corporate
- Thread Author
- #1
<p>In the world of industrial automation, virtual controllers have rapidly become a rising trend, especially in recent years. With the widespread adoption of digital twin technologies, multi-core processors, and factory floor applications, manufacturers have started to embrace this innovative approach more warmly. But what exactly do virtual controllers mean, and how do you know if they are suitable for your production operations?</p>
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<h3>💡 What are Virtual Controllers and Hypervisors?</h3>
<p>Virtual controllers and hypervisors are terms frequently heard in the virtualization of automation systems. Simply put:</p>
<ul>
<li>Hypervisor: A thin operating system that runs on hardware and can host virtual machines or virtual devices (including controllers). Alternatively, it can be software running on a standard Windows operating system that enables controller virtualization. Essentially, it's software that allows you to run a virtual system on a machine with sufficient RAM and storage.</li>
<li>Virtual Controller: A software-based version of a PLC (Programmable Logic Controller). It has proven useful in laboratory, development, and quality environments. Its use on the production floor is still new and continues to expand.</li>
</ul>
<p>Recently, edge devices have also emerged, bringing virtualization closer to the equipment to reduce latency. However, even in this scenario, having a very robust network infrastructure is critically important.</p>
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<h3>✅ Are You Ready to Transition to Virtual Controllers? 🚩</h3>
<p>There are some signs and "red flags" to consider that indicate whether a manufacturing facility is ready to transition to virtual control systems:</p>
<ul>
<li>Scalable and Repeatable Processes: If you have scalable and repeatable processes, such as a tank farm with similar tanks or a packaging line, these present great opportunities for virtualization.</li>
<li>In-house Expertise: Having in-house IT or OT expertise to manage a virtualized system is crucial. If these resources are not available within the company, support from external partners, such as system integrators, may be necessary.</li>
<li>Complex or Time-Critical Operations: Production processes that use complex systems or highly time-critical operations may not be the best option for a virtualized system. Latency issues can occur in such applications.</li>
<li>Lack of Experience: If you haven't worked much with this technology before, it would be wiser to conduct experiments on a laboratory scale rather than deploying it directly in production.</li>
<li>Network Infrastructure: Virtualization adds an extra layer of complexity to your networks. Therefore, you should carefully examine the suitability of your existing network infrastructure for virtualization technology.</li>
</ul>
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<h3>🛠️ Modernization and Virtualization in Existing Facilities</h3>
<p>Here are the steps to follow when deciding whether to transition to virtualization in modernization projects for existing facilities with older control systems:</p>
<ul>
<li>Assess Existing Infrastructure: First, honestly review your current hardware and technology infrastructure. Check for the risk of failure in old hardware and the condition of 5-15 year old network switches and Ethernet/fiber cables.</li>
<li>Fundamental Updates: Older control and network technologies may not be immediately ready for virtualization. Therefore, focus on critical updates to your control and network hardware first.</li>
<li>Evaluate Internal Resources: There may be IT experts within the company experienced in virtualization for front-office applications like file servers or email. However, IT expertise and OT (Operational Technology) system expertise are different. Consider the capabilities of your OT personnel to support virtualization efforts.</li>
<li>External Support: If you plan to seek external help, ensure that 24/7 support agreements are in place.</li>
<li>Process Complexity: Evaluate the most critical aspects of your production process. Do you have complex processes like multi-axis robots, or simpler discrete manufacturing processes? For complex processes, it is recommended to upgrade your core systems before virtualization. For simpler processes, implementing virtualization incrementally may be more appropriate.</li>
</ul>
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<h3>⚡ Latency and Deterministic Constraints</h3>
<p>When it comes to automated systems that virtual controllers will connect to, certain latency or deterministic constraints can make specific production processes unsuitable for virtualization.</p>
<ul>
<li>In environments like robotics or multi-axis control, there are deterministic concerns to ensure that command and control occur as expected.</li>
<li>With virtualization, moving the decision-making point from the production floor to higher layers of the network, typically to servers in a data center, may require passing through multiple switches, which can cause communication delays.</li>
</ul>
<p>However, today, thanks to edge devices, it is possible to reduce this latency by positioning virtualization closer to the equipment. Nevertheless, having a very robust network is essential. Generally, it is best for your virtualized system to be local to the facility and process it controls, rather than being cloud-based.</p>
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<p>Virtual controller technology, with proper planning and infrastructure, can provide significant benefits to your production operations. However, as with any technological innovation, carefully evaluating your current situation and needs is key to a successful transition.</p>
