Methods and apparatus to design collaborative automation systems based on Data Distribution Service middleware are described, which include a clustered automation platform having one or more control servers connected to a local area control network, and a plurality of self-contained process interface systems configured to receive electrical signals from one or more field instruments and forward resulting data via an uplink to a local area input/output network. The clustered automation platform also includes an input/output processing and inferential modeling server connected to the local area input/output network and configured to process input/output signals of the plurality of self-contained process interface systems. The clustered automation platform also includes real-time data distribution service control middleware configured to interconnect one or more process control applications, the one or more input/output processing and inferential modeling servers, the one or more control servers, the plurality of self-contained process interface systems, and one or more HMIs.

Methods and apparatus to design collaborative automation systems based on Data Distribution Service middleware are described, which include a clustered automation platform having one or more control servers connected to a local area control network, and a plurality of self-contained process interface systems configured to receive electrical signals from one or more field instruments and forward resulting data via an uplink to a local area input/output network. The clustered automation platform also includes an input/output processing and inferential modeling server connected to the local area input/output network and configured to process input/output signals of the plurality of self-contained process interface systems. The clustered automation platform also includes real-time data distribution service control middleware configured to interconnect one or more process control applications, the one or more input/output processing and inferential modeling servers, the one or more control servers, the plurality of self-contained process interface systems, and one or more HMIs.

A sensor comprises a matrix switch that includes a number of switching elements configured in a matrix configuration. The sensor comprises one or more sensor elements configured in a sensor matrix configuration. A controller operates to dynamically select one or more signal routes via the switching elements to communicate data from one or more sensor elements of the sensor matrix. The matrix switch can operate to dynamically route multiple signal routes between sensor elements of the sensor to another component based on a set of criteria.

A collaborative automation platform and associated method include a fault-tolerant control server hosting one or more virtual controllers, and a fault-tolerant input/output server hosting a virtual input/output system. The collaborative automation platform also includes a master autonomous process interface system connected to the virtual input/output system, via a local area input/output network. The collaborative automation platform also includes a plurality of distributed autonomous process interface systems connected to the master autonomous process interface system, wherein each distributed autonomous process interface system is hardwired to a plurality of field instruments. The collaborative automation platform also includes real-time DDS middleware configured for execution with the fault-tolerant control server, the fault-tolerant input/output server, the master autonomous process interface system, and the plurality of distributed autonomous process interface systems.

A collaborative automation platform and associated method include a fault-tolerant control server hosting one or more virtual controllers, and a fault-tolerant input/output server hosting a virtual input/output system. The collaborative automation platform also includes a master autonomous process interface system connected to the virtual input/output system, via a local area input/output network. The collaborative automation platform also includes a plurality of distributed autonomous process interface systems connected to the master autonomous process interface system, wherein each distributed autonomous process interface system is hardwired to a plurality of field instruments. The collaborative automation platform also includes real-time DDS middleware configured for execution with the fault-tolerant control server, the fault-tolerant input/output server, the master autonomous process interface system, and the plurality of distributed autonomous process interface systems.

A smart power system is described. In one or more implementations, the smart power system comprises a microcontroller and a power converter electrically connected to the microcontroller and is configured to convert electrical energy from one form to another. The system also includes a switch element electrically connected to the microcontroller and configured to control distribution of the converted electrical energy to an electrical load. A sense element is electrically connected to the electrical load and to the microcontroller and is configured to monitor the converted electrical energy distributed to the electrical load and to furnish a feedback signal based upon the converted electrical energy. The microcontroller is configured to verify and to monitor the power converter, as well as to control and to monitor distribution of the converted electrical energy to the electrical load based upon the feedback signal.

A smart power system is described. In one or more implementations, the smart power system comprises a microcontroller and a power converter electrically connected to the microcontroller and is configured to convert electrical energy from one form to another. The system also includes a switch element electrically connected to the microcontroller and configured to control distribution of the converted electrical energy to an electrical load. A sense element is electrically connected to the electrical load and to the microcontroller and is configured to monitor the converted electrical energy distributed to the electrical load and to furnish a feedback signal based upon the converted electrical energy. The microcontroller is configured to verify and to monitor the power converter, as well as to control and to monitor distribution of the converted electrical energy to the electrical load based upon the feedback signal.

A collaborative automation platform and associated method include a fault-tolerant control server hosting one or more virtual controllers, and a fault-tolerant input/output server hosting a virtual input/output system. The collaborative automation platform also includes a master autonomous process interface system connected to the virtual input/output system, via a local area input/output network. The collaborative automation platform also includes a plurality of distributed autonomous process interface systems connected to the master autonomous process interface system, wherein each distributed autonomous process interface system is hardwired to a plurality of field instruments. The collaborative automation platform also includes real-time DDS middleware configured for execution with the fault-tolerant control server, the fault-tolerant input/output server, the master autonomous process interface system, and the plurality of distributed autonomous process interface systems.

A collaborative automation platform and associated method include a fault-tolerant control server hosting one or more virtual controllers, and a fault-tolerant input/output server hosting a virtual input/output system. The collaborative automation platform also includes a master autonomous process interface system connected to the virtual input/output system, via a local area input/output network. The collaborative automation platform also includes a plurality of distributed autonomous process interface systems connected to the master autonomous process interface system, wherein each distributed autonomous process interface system is hardwired to a plurality of field instruments. The collaborative automation platform also includes real-time DDS middleware configured for execution with the fault-tolerant control server, the fault-tolerant input/output server, the master autonomous process interface system, and the plurality of distributed autonomous process interface systems.

A smart power system is described. In one or more implementations, the smart power system comprises a microcontroller and a power converter electrically connected to the microcontroller and is configured to convert electrical energy from one form to another. The system also includes a switch element electrically connected to the microcontroller and configured to control distribution of the converted electrical energy to an electrical load. A sense element is electrically connected to the electrical load and to the microcontroller and is configured to monitor the converted electrical energy distributed to the electrical load and to furnish a feedback signal based upon the converted electrical energy. The microcontroller is configured to verify and to monitor the power converter, as well as to control and to monitor distribution of the converted electrical energy to the electrical load based upon the feedback signal.