Method and apparatus for alternative communication paths via a connection network

Abstract

A method for sending and receiving data between a first network node and a second network node using an alternative communication path is disclosed. The method includes: establishing a first communication path between the first network node and the second network node, the first communication path sending and receiving data between the first network node and the second network node; and establishing a second communication path between the first network node and the second network node, the second communication path sending and receiving data between the first network node and the second network node. A diagnostic program tests network failures of the first communication path and the second communication path, so that when a network failure in the first communication path and the second communication path is detected, the alternative network path sends and receives data between the first network node and the second network node, and alerts a technician that the failure and the first communication path and the second communication path need to be repaired. After repairing the failure, the first communication path and the second communication path resume normal operation.

Description

Technical Field

[0001] The present disclosure generally relates to industrial process control and automation systems. More specifically, the present disclosure relates to a method and apparatus for facilitating an alternative communication path for connecting networks. Background Art

[0002] Industrial process control and automation systems are commonly used to automate large and complex industrial processes. These types of systems typically include sensors, actuators, controllers, and other intelligent electronic devices for supervisory control and data acquisition. The intelligent electronic devices in such systems are interconnected and communicate via a LAN (local area network) or WAN (wide area network). In such industrial process control and automation systems, the architecture may include gateways connected to I / O devices such as sensors and actuators that are not directly connected to the controller, such as those used in the automation system. High-availability applications for control and supervisory process control and automation systems operating within a LAN or WAN expect network access to all intelligent electronic devices in the network in order to avoid communication interruptions. Such as, for example, a parallel redundancy protocol (PRP) network system and a high-availability seamless redundancy (HSR) network system.

[0003] Process controllers used in industrial process control and automation systems can separate their I / O devices from the controller through a redundant Ethernet LAN network to a traditional backplane. The PRP network system uses two independent dedicated networks to transmit control signals and data between the controller and the I / O devices that can be connected to separate nodes of the network. The PRP network system duplicates the data frame to be transmitted, and adds a unique sequence number to the end of each standard communication data packet in the standard communication data packet, and sends the two PRP frames through two independent LANs or WANs with similar network topologies. This communication method has advantages over traditional non-PRP redundant networks because if a failure occurs on one LAN, control of the I / O connection can be quickly restored using the redundant path. For example, the recovery time for switching in the redundant path of PRP is microseconds, while the recovery time of traditional non-PRP redundant networks is seconds.

[0004] However, if the LAN A cable associated with the controller experiences a fault, such as, for example, a broken wire, a faulty connector, or a failure of the Ethernet switch attached to LAN A, and the parallel LAN B associated with the I / O device nodes experiences a similar fault as explained above, the PRP network will suffer a failure, resulting in a loss of control of the automation system. In this case, there will be no PRP network path from the controller to the I / O device, resulting in a possible loss of control of the I / O device and a loss of visibility to the I / O.

[0005] It would therefore be advantageous to provide an alternative network path around the failed LAN A and LAN B PRP networks that could route control and I / O traffic between the controller in the control node to the connected devices in its I / O nodes and continue normal operation until the failure can be diagnosed and repaired. Summary of the invention

[0006] The present disclosure relates to a method and system for facilitating a parallel redundancy protocol in an industrial process control and automation system.

[0007] In a first embodiment, a device for sending and receiving data between a first network node and a second network node on an alternative communication path is disclosed. The device includes: a first network, the first network connecting the first network node to the second network node, thereby establishing a first communication path for sending and receiving data between the first network node and the second network node. A second network, the second network connecting the first network node to the second network node, thereby establishing a second communication path for sending and receiving data between the first network node and the second network node. A third network is connected to the first node and the second node to form an alternative network path. The first network, the second network, and the third network do not intersect with each other. When a failure of the communication path in the first network and the second network is detected, a diagnostic program causes the alternative network path to send and receive data between the first network node and the second network node.

[0008] In a second embodiment, a method for sending and receiving data between a first network node and a second network node using an alternative communication path is disclosed, the method comprising establishing a first communication path between the first network node and the second network node, the first communication path sending and receiving data between the first network node and the second network node. The method further comprises establishing a second communication path between the first network node and the second network node, the second communication path sending and receiving data between the first network node and the second network node, and establishing a third communication path between the first network node and the second network node, the third communication path forming an alternative communication path. The first communication path, the second communication path, and the third communication path do not intersect with each other. The method comprises testing a network failure of the first communication path and the second communication path, and when a network failure in the first communication path and the second communication path is detected, causing the alternative communication path to send and receive data between the first network node and the second network node.

[0009] In a third embodiment, a non-transitory computer-readable medium containing instructions for sending and receiving data on an alternative communication path connected between a first network node and a second network node is disclosed, which, when executed, causes at least one processing device to send and receive data between the first network node and the second network node using a first communication path between the first network node and the second network node, and to send and receive data between the first network node and the second network node using a second communication path between the first network node and the second network node, in order to test a network failure of the first communication path and the second communication path using a diagnostic program, and when a network failure in the first communication path and the second communication path is detected, send and receive data between the first network node and the second network node using the alternative communication path.

[0010] Other technical features will be apparent to those skilled in the art from the following drawings, descriptions and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more complete understanding of the present disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:

[0012] Figure 1 An exemplary industrial process control and automation system according to the present disclosure is shown;

[0013] Figure 2 An exemplary control group consisting of a controller in a first network node communicating with a gateway in a second network node according to the present disclosure is shown;

[0014] Figure 3 An exemplary controller of an industrial process control and automation system according to the present disclosure is shown;

[0015] Figure 4 An exemplary schematic diagram of a PRP network for transmitting supervisory control signals and data between a node 1 and a node 2 according to the present disclosure is shown;

[0016] Figure 5 An exemplary schematic diagram of a PRP interface module implementing a PRP network according to the present disclosure is shown; and

[0017] Figure 6 An exemplary architecture for providing service analysis and reporting failures of a PRP network according to the present disclosure is shown. DETAILED DESCRIPTION

[0018] These figures (discussed below) and the various embodiments used to describe the principles of the present invention in this patent document are provided by way of illustration only and should not be construed as limiting the scope of the present invention in any way. Those skilled in the art will appreciate that the principles of the present invention can be implemented in any type of suitably arranged device or system.

[0019] Figure 1 1 shows a portion of an exemplary industrial process control and automation system 100 according to the present disclosure. Figure 1 As shown, system 100 includes various components that facilitate the production or processing of at least one product or other material. For example, system 100 can be used to facilitate the control or monitoring of components in one or more industrial plants. Each plant represents one or more processing facilities (or one or more parts thereof), such as one or more manufacturing facilities for producing at least one product or other material. In general, each plant can implement one or more industrial processes and can be referred to as a process system individually or collectively. A process system generally represents any system or part of a system that is configured to process one or more products or other materials or energy in different forms in some manner.

[0020] exist Figure 1 In the example shown, the system 100 includes one or more sensors 102a and one or more actuators 102b. The sensors 102a and actuators 102b represent components in a process system that can perform any of a variety of functions. For example, the sensor 102a can measure a variety of characteristics in the process system, such as temperature, pressure, or flow. In addition, the actuator 102b can change a variety of characteristics in the process system. Each sensor in the sensor 102a includes any suitable structure for measuring one or more characteristics in the process system. Each actuator in the actuator 102b includes any suitable structure for operating or affecting one or more conditions in the process system.

[0021] At least one input / output (I / O) module 104 is coupled to the sensor 102a and the actuator 102b. The I / O module 104 facilitates interaction with the sensor 102a, the actuator 102b, or other field devices. For example, the I / O module 104 can be used to receive one or more analog inputs (AI), digital inputs (DI), digital input sequence of events (DISOE), or pulse accumulator inputs (PI) or provide one or more analog outputs (AO) or digital outputs (DO). Each I / O module 104 includes any suitable structure for receiving one or more input signals from one or more field devices or providing one or more output signals to one or more field devices. Depending on the implementation, the I / O module 104 may include a fixed number and type of inputs or outputs or reconfigurable inputs or outputs. In Figure 1In an exemplary system of FIG. 1 , I / O modules 104 are connected to gateways 106 via a network 108. Gateways 106 receive supervisory control information from remotely located controllers 116. Gateways 106 serve as entry and exit points for network nodes. Control information and all data must pass through or communicate with a gateway before being routed from a node. For example, control information from a controller 116 may be sent from the controller 116 to an actuator 102 b via one or more gateways 106. Data from sensors 102 a is transmitted to one or more controllers 116 via one or more gateways 106.

[0022] For example, a first set of controllers 116 can use measurements from one or more sensors 102a to control the operation of one or more actuators 102b. These controllers 116 can interact with sensors 102a, actuators 102b, and other field devices via I / O modules 104. The controllers 116 can be coupled to the I / O modules 104 via Ethernet, backplane communications, serial communications, etc. A second set of controllers 116 can be used to optimize control logic or other operations performed by the first set of controllers. A third set of controllers 116 can be used to perform additional functions.

[0023] Controllers 116 may be used in the system 100 to perform various functions in order to control one or more industrial processes. For example, a first set of controllers 116 operating as a first network node may control the operation of one or more actuators 102b using measurements from one or more sensors 102b, which are sent from a gateway 106 operating as a second (and separate) network node. These controllers 116 may interact with sensors 102a, actuators 102b, and other field devices via the gateway 106 and I / O modules 104. In addition, the controllers 116 may also communicate with sensors and actuators (not shown) that may be connected to the I / O modules 114 in the first network node.

[0024] Controllers 116 are usually arranged in layers in the system. For example, different controllers 116 can be used to control individual actuators, a collection of actuators forming a machine, a collection of machines forming a unit, a collection of units forming a plant, and a collection of plants forming an enterprise, which are directly connected in their network nodes or connected to different network nodes via gateways 106. A specific example of a hierarchical arrangement of controllers 116 is defined as the "Purdue" model of process control. Controllers 116 in different hierarchical levels can communicate via one or more networks 108 and associated switches, firewalls, and other components.

[0025] Each controller 116 includes any suitable structure for controlling one or more aspects of an industrial process. At least some of the controllers 106 may, for example, represent proportional integral derivative (PID) controllers or multivariable controllers, such as profit controllers or other types of controllers that implement model predictive control or other advanced predictive control. As a specific example, each controller 116 may represent a computing device running a real-time operating system, a MICROSOFT WINDOWS operating system, or other operating system. Operator access and interaction with the controllers 116 and other components of the system 100 may be performed via various operator stations 110.

[0026] Each operator station 110 may be used to provide information to an operator and to receive information from an operator. For example, each operator station 110 may provide information to an operator identifying the current state of an industrial process, such as the values ​​of various process variables and warnings, alarms, or other states associated with the industrial process. Each operator station 110 may also receive information that affects how the industrial process is controlled, such as by receiving set points for process variables controlled by the controller 106 or receiving other information that changes or affects how the controller 106 controls the industrial process. Each operator station 110 includes any suitable structure for displaying information to an operator and interacting with an operator.

[0027] This represents a brief description of one type of industrial process control and automation system that can be used to manufacture or process one or more materials. Additional details about industrial process control and automation systems are well known in the art and are not required for understanding the present disclosure. In addition, industrial process control and automation systems are highly configurable and can be configured in any suitable manner according to specific needs.

[0028] Although Figure 1 A portion of an exemplary industrial process control and automation system 100 is shown, but may be Figure 1 Make various changes. For example, they can be combined, further subdivided, reorganized or omitted Figure 1 In addition, although Figure 1 One exemplary operating environment in which redundant controllers may be used is shown, but this functionality may be used in any other suitable system.

[0029] Figure 2 An exemplary control group 200 is shown, which consists of a controller 202 in a first network node communicating with a gateway 204 in a second network node along one or more networks 108. For ease of explanation, the control group 200 is described as Figure 1The control group 200 is used in the industrial process control and automation system 100 of the present invention. However, the control group 200 can be used in any other suitable system. The exemplary control group 200 operates at Level 1 of the Purdue model, and among other things, the exemplary control group 200 can use the measurement results from one or more sensors 102a to control the operation of one or more actuators 102b.

[0030] like Figure 2 As shown, the control group 200 includes a controller 202 and a gateway 204. The controller 202 may represent Figure 1 The gateway 204 may represent or be represented by various controllers in the controller 116. Figure 1 106 of the gateways 106 of the present invention or represented by these gateways. The controller 202 and the gateway 204 are connected to one or more networks 108, such as FTE (fault tolerant Ethernet), IEC-61850, Ethernet / IP or MODBUS / TCP networks. The controller 202 can communicate with sensors and implement control logic for controlling actuators within its own network node. The controller 202 can also communicate with the gateway 106 and the sensor 102a and implement control logic for controlling the actuator 102b within the second network node of the gateway 204.

[0031] In an embodiment of the present disclosure, a dedicated network facilitates communication between the controller 202 and the gateway 204. The dedicated network can transmit supervisory control and data between the controller 202 and the gateway 204, thereby allowing the controller 202 to access and control sensors and actuators of the second network nodes.

[0032] The dedicated network includes any suitable structure for transmitting data between networked devices, such as a parallel redundancy protocol (PRP) network operating under IEC standard 62439-3. For example, each controller 202 can be configured as a node that communicates between gateways 204 using two independent PRP networks. Supervisory control and process data can be transmitted and received along the two independent networks between the controller 202 and the gateway 204. Each controller 202 includes any suitable structure configured to perform control operations in an industrial process control and automation system.

[0033] although Figure 2 An example of a controller group 200 having redundant process controllers for an industrial control network is shown, but may be used for Figure 2 Various changes may be made. For example, controller group 200 may include more or fewer controllers. In addition, any suitable number and configuration of other network devices may be used to interconnect controllers in a controller group or controller node.

[0034] Figure 3 Shows Figure 22 is a schematic diagram of an example of a controller 202 of a controller node shown in FIG. The controller 202 may be, for example, represented in Figure 1 Any of the controllers 116 or other control system components used in a redundant configuration in . However, the controller 202 may represent any other suitable device that supports operating in a redundant manner, regardless of whether the device 202 is used for process control and automation.

[0035] like Figure 3 As shown in FIG, the controller 202 includes at least one processor 205, at least one storage device 204, at least one communication unit 206, and at least one I / O unit 208. Each processor 205 can execute instructions, such as those that can be loaded into the memory 210. Each processor 202 represents any suitable processing device, such as one or more microprocessors, microcontrollers, digital signal processors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or discrete circuits.

[0036] Memory 210 and persistent storage 212 are examples of storage devices 204, which represent any structure capable of storing information (such as data, program code, and / or other suitable information, whether temporary or permanent) and facilitating retrieval of the information. Memory 210 may represent random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 212 may include one or more components or devices that support longer-term storage of data, such as read-only memory, a hard drive, flash memory, or an optical disk.

[0037] The communication unit 206 supports communication with other systems or devices. For example, the communication unit 206 may include at least one network interface card or a wireless transceiver to facilitate communication via at least one wired or wireless network. As a specific example, the communication unit 206 may support communication with one or more sensors 102a or one or more actuators 102b via the I / O network 108. As another specific example, the communication unit 206 may support communication with higher-level components via the network 108. The communication unit 206 may support communication via any suitable physical or wireless communication link.

[0038] The I / O unit 208 allows for the input and output of data. For example, the I / O unit 208 can provide a connection for user input via a keyboard, mouse, keypad, touch screen, or other suitable input device. The I / O unit 208 can also send output to a display, printer, or other suitable output device. However, it should be noted that the I / O unit 208 may not be required for local I / O, such as when the controller 202 is locally accessible or remotely accessible via a network connection.

[0039] As described in more detail below, the processor 205 of the controller 202 may be used to execute a diagnostic system that tests the operational functionality of the controller 202. The processor 205 of the controller 202 may also be used to execute algorithms that support the transfer of data from the controller 202 to a redundant device, such as to an associated redundant process controller 116.

[0040] although Figure 3 An example of a controller 202 for implementing the present disclosure is shown, but may be used for Figure 3 Make various changes. For example, you can combine, further subdivide or omit Figure 3 The computing device may have various configurations, and additional components may be added as needed. Figure 2 The present disclosure is not limited to any particular configuration of devices.

[0041] Figure 4 A dedicated network for transmitting data between the controller 202 and the gateway 204 according to an embodiment of the present disclosure is shown. The first network node 1 is formed by the controller 202, the local I / O module 114 and the PRP interface module 502. The second network node 2 is formed by the gateway 204, the I / O module 104b and the interface module 504.

[0042] The controller 202 can communicate with the network 108 via one or more networks 108 (such as Figure 1 The network 108 shown in FIG. 1 and associated switches, firewalls connected to Figure 1 The sensors 102a and actuators 102b of the control group are connected to the I / O modules 104b and to the associated gateways 204 via one or more networks 103, as described above. Figure 1 . The PRP network uses two independent LAN networks connected between the PRP interface modules 502, 504 to send data from the controller 202 of node 1 to the gateway 204 and I / O module 104b of node 2. For example, the PRP interface module 502 associated with the network of node 1 communicates using a first network (hereinafter referred to as LAN A), which includes a first cable A connected between the module 502 and the Ethernet switch A 402 and a second cable A' connected from the Ethernet switch A 402 to the interface module 504. The interface module 502 is further connected to the second network (hereinafter referred to as LAN B) via a first cable B to the Ethernet switch B 404 and a second cable B' connected to the interface module 504. The PRP interface modules 502, 504 establish two separate private networks LAN A and LAN B between node 1 and node 2 through their associated Ethernet switches 402, 404.

[0043] As previously explained, if the LAN A cable associated with Node 1 experiences a fault, such as, for example, a broken wire, a faulty connector, or an Ethernet switch 402 failure, and at the same time the LAN B cable associated with Node 2 experiences a similar fault as explained above, a PRP network such as the one described above will suffer a failure, resulting in a loss of control of the automation system. In this case, there will be no PRP network path from the controller 202 in Node 1 to the I / O module 104 b in Node 2, and vice versa. To correct for such a loss of network communications between Node 1 and Node 2, each PRP interface 502 and 504 also includes a connection to the network 108 of the industrial process control and automation system.

[0044] like Figure 4 , the PRP interface module 502 associated with Node 1 includes a connection to the network 108. Similarly, the PRP interface 504 associated with Node 2 includes a similar connection to the network 108. When a failure in LAN A and LAN B is detected that cuts off or severely degrades the PRP network, this alternate communication path through the network 108 can be used to send control signals and data packets between Node 1 and Node 2. The alternate communication path can be used to transmit control and data between Node 1 and Node 2 until the PRP network is diagnosed and the failure in the PRP network is repaired.

[0045] Figure 5 An example of a PRP interface module 502, 504 operating under IEC standard 62439-3 is shown. Each of the two PRP interface modules 502, 504 includes a first dual-attached node (DANP1) 502, which is labeled as node 1 in this disclosure. The second dual-attached node (DANP2) 504 is labeled as node 2. In this example, node 1 is associated with controller 202 and will be described as a source node, and node 2 is associated with gateway 204 and I / O module 104b and will be described as a destination node.

[0046] Each PRP interface module 502, 504 includes a processor 500 in the upper layer of the interface module 502, 504, which includes one or more processors or other processing devices that can execute operating system instructions such as a protocol stack 501. The protocol stack 501 can be implemented in the hypertext transfer protocol (HTTP) and can include the transmission control protocol (TCP) at the transport layer 503 and the IP Internet Protocol (IP) at the network layer 505. These IEC protocol layer examples should be considered non-limiting and are merely illustrative of the types of communication protocols that can be implemented by the protocol stack and operated by the processor 500 of each PRP interface module 502, 504. A diagnostic layer 506 is also included in the upper layer of the interface module 502, 504. The diagnostic layer 506 checks for faults in the wiring, connections, switches, and other physical devices that make up LAN A and LAN B.

[0047] Each PRP interface module 502, 504 further includes a TX / RX circuit system 507 that implements the PRP-related functions described herein as they relate to the communication stack of the link redundancy entity (LRE) 508 of the IEC standard 62439-3. As described in IEC 62439-3, to achieve redundancy, a PRP-compatible node is connected to two independent network LANs having similar topologies (e.g., a first independent network consisting of LAN A and a second independent network consisting of LAN B) through two independent physical ports (Port A and Port B). The physical ports include circuit systems such as the transmission (TX) circuit system and the reception (RX) circuit system 507 for handling the physical connectivity of the corresponding node 1 and node 2 connections.

[0048] Each pair of ports A and B for the same node share the same MAC address and operate in parallel with each other. Each pair of ports A and B is attached to the protocol stack 501 of the upper layer of its corresponding PRP interface module through LRE 508. LRE 508 ensures that the upper layer is not aware of redundancy and is not affected by redundancy. LRE 508 performs two key tasks related to the PRP related functions described herein, LRE 508 handles the duplication of PRP frames, and manages the acceptance of received packets from LAN A and LAN B.

[0049] For example, the task assigned to the upper layer of the protocol stack 501 is to attach a MAC header to a data packet and convert the data packet into an IEEE 802.3 frame, as done in a non-redundant network. The MAC header includes a source MAC address field, a destination MAC address field, and other fields, such as a tag and Ethernet type / size field for an Ethernet frame. Typically, LRE508 uses the same destination MAC address for a destination within the network. LRE 508 replicates the data frame received from the upper layer and attaches a redundancy check tail (RCT) to each replicated data frame. Then, LRE 508 transmits the data packet frame to the transmitter of port A associated with LAN A and the transmitter of port B associated with LAN B. In this embodiment, packets from port A and port B are sent to PRP interface 509 to be transmitted to destination node 2 using both LAN A and LAN B.

[0050] The two PRP frames travel through LAN A and LAN B with different delays and ideally both arrive at destination Node 2 and are processed by PRP interface 509 and Port A and Port B RX circuitry and LRE 508 of PRP interface module 504. LRE 508 of Node 2 processes the PRP frame that arrives first and removes the second frame if it arrives. In this example, the MAC address of source Node 1 is used to identify the received PRP frame.

[0051] The PRP source node and destination node just explained use the node 1 PRP interface module 502 associated with the controller 202 as the source node, and use the node 2 PRP interface module 504 associated with the gateway 204 and the I / O module 104b as the destination node. The PRP network of the present invention is also operable to provide data from node 2 to the controller 202. For example, data from the I / O module 104b provided by the sensor 102a and other devices connected to the I / O module 104b is processed, thereby operating node 2 as a source node and node 1 as a destination node. For example, two replicated PRP frames from the LRE 508 of node 2 are applied to the port A and port B TX circuit systems 507 and the PRP interface 509 to travel through LAN A and LAN B, and are received by the port A and port B of the RX circuit system 507 of node 1, respectively, to be processed by the LRE 508 of node 1, as explained above.

[0052] Each PRP interface module 502, 504 includes a diagnostic layer 506 in the upper layer of each interface module, which routinely performs network integrity checks of LAN A and LAN B when in operation. When a failure of LAN A and LAN B is detected, the diagnostics can independently initiate switching to send and receive PRP frames along the network (NTW) 108. It should be noted that the NTW 108 can be one or more separate FTE (Fault Tolerant Ethernet), IEC-61850, Ethernet / IP or MODBUS / TCP networks or Figure 1 and Figure 2 . The processor 500 executing the diagnostic layer 506 will periodically query the integrity of LAN A and LAN B to detect whether a failure has occurred. For example, the processor 500 of the node 1 PRP interface module 502 will periodically send a "heartbeat" message packet along LAN A to the processor 500 of the node 2 diagnostic layer 506. Similarly, the processor 500 of the node 2 PRP interface module 504 will periodically send a "heartbeat" message packet along LAN B to the processor 500 of the node 1 diagnostic layer 506. In another example, the diagnostic layer 506 of each node may transmit a frame error rate signal on the corresponding LAN A or LAN B to detect any failure in the LAN A and LAN B networks. Other diagnostic methods known in the industry for testing Ethernet networks to diagnose the integrity of the communication path can be used to detect failures in LAN A and LAN B.

[0053] After detecting a failure in both LAN A and LAN B, diagnostic layer 506 may command a switch using NTW 108 to transmit data packets between Node 1 and Node 2. Figure 5 , the diagnostic layer 506 of Node 1 will send a diagnostic message transmitted on the NTW 108 to the Node 1 NTW interface 510 after detecting a failure in LAN A. The diagnostic message is addressed to the network interface 510 and diagnostic layer 506 of Node 2, thereby notifying Node 2 of the failure of LAN A. If Node 2 LAN B is operating normally, no action is taken to switch the LAN A network to use the alternative communication path of the NTW 108 network. However, the diagnostic layer 506 of Node 1 502 will also send a fault message to the controller 202 via the NTW interface 510 and NTW 108, thereby notifying the controller 202 of the failure of LAN A.

[0054] Similarly, the diagnostic layer 506 of Node 2, upon detecting a failure in LAN B, will send a diagnostic message to the interface 510 and diagnostic layer 506 of Node 1 via the NTW interface 510 and NTW 108 of Node 2, thereby notifying Node 1 of the failure of LAN B. If LAN A is operating normally, no action is taken to switch the LAN B network to use the NTW 108 as an alternative communication path. However, the diagnostic layer 506 of Node 2 will also send a fault message to the controller 202 via the network interface 510 and NTW 108 network.

[0055] However, if both diagnostic layers 506 report a fault or failure of each of LAN A and LAN B, a switchover procedure is implemented in each node to use NTW 108 as an alternate communication path to send PRP control and data between Node 1 and Node 2. Figure 5 , upon detecting the failure of the LAN A and LAN B networks, each processor 500 of each PRP interface module 502, 504 will send a signal to its corresponding PRP interface 509 to switch and use an alternative network route to send and receive PRP frames between Node 1 and Node 2. For example, the PRP interface module 502 acting as a source will cause the diagnostic layer 506 to instruct the PRP interface 509 to stop sending and receiving network traffic through the PRP interface 509, and establish a direct communication path along the connection 512 to the NTW interface 510 and start sending and receiving network traffic from the NTW interface 510 of Node 1. Similarly, the PRP interface module 504 acting as a destination will cause the diagnostic layer 506 to instruct the PRP interface 509 to start sending and receiving network traffic from the NTW interface 510 of Node 2.

[0056] Node 1's NTW interface 510 will transfer PRP frames received from TX A circuitry 507 to Node 2's NTW interface 510 via NTW interface 510 and NTW 108. NTW interface 510 will transfer received PRP frames from NTW interface 510 to Node 2 interface 509 via connection 512 and RX A circuitry 507 for processing by LRE 508. When acting as a source, PRP frames from Node 2 will similarly be sent along NTW 108 from Node 2 NTW interface 510 to PRP interface 509 RX A circuitry 507 for processing by Node 1's LRE 508.

[0057] For ease of explanation, the present disclosure has been explained as an alternative network path with only one NTW 108 path. However, most modern Ethernet networks used in factories operate using a fault-tolerant system, including a second redundant network NTW 108 path to carry duplicated traffic (not shown). The present disclosure can be used to simultaneously carry duplicated PRP frames from a node acting as a source to a node acting as a destination using the Port B channel TX / RX circuit system 507 along the second redundant network of the NTW 108 path in the same manner as explained above for the Port A channel.

[0058] The diagnostic layer 506 of each PRP interface module 502, 504 will continue to test each LAN A and LAN B to restore the PRP network. As previously explained, the diagnostic layer 506 will continue to send fault messages of the status of each LAN A and LAN B to the controller 202 via the NTW 108.

[0059] Figure 6 600 is an exemplary architecture for providing service analysis and reporting faults of a PRP network according to the present disclosure. For ease of explanation, the architecture 600 may be described as Figure 5 The controller 202 uses Figure 3 However, Figure 6 The architecture 600 shown in FIG. 6 may be used with any suitable device and in any suitable system.

[0060] In this example, the architecture 600 includes a processor 607 that executes one or more control algorithms 608 stored in a control database 606, which represents a memory location in the primary writable memory of the persistent storage 212 or other storage device 204. Each control algorithm 608 can be used to control one or more aspects of at least one industrial process. One operation of at least one of the control algorithms 308 is to track and send data to the I / O modules 104 and sensors 102a and actuators 102b and other devices associated with the controller 202. NTW 108 represents an Ethernet network, such as, for example, Figure 1 NTW 108 is connected to controller 202 via communication unit 608, which can be Figure 3 The communication unit 208 of the controller 202 is shown in FIG.

[0061] The processor 607 also includes and executes a failure detection diagnostic algorithm 625. The processor 607 and the failure detection diagnostic 625 will receive fault messages transmitted from the interface modules 502 and 504 along the NTW 108. The processor 607 is further connected to the enabled service manager 630. The fault messages and any diagnostic data received with the fault messages are processed by the fault detection diagnostic 625 and sent to and reviewed by the enabled service manager 630. The enabled service manager 630 will log faults found in the PRP network as diagnostic events and prioritize detected faults based on criticality.

[0062] Prioritizing detected faults may include organizing the collected faults so that the most important (e.g., urgent) faults can be handled first. For example, detecting a failure only on LAN A or only on LAN B will still allow message traffic to be sent between Node 1 and Node 2. This will be registered as a non-urgent, low priority fault. However, a complete failure of both LAN A and LAN B will be prioritized as an urgent or high priority failure. Fault messages sent by Node 1 and Node 2 may also include diagnostic data, which may include abnormal parameters. Diagnostic data containing abnormal parameters that severely exceed (e.g., are significantly below or above) threshold limit values ​​may be listed first to establish an order. Detected faults that are reported to exist may also be verified to ensure their existence. Verifying the diagnostic data of the detected faults may include comparing the collected diagnostic data with past data, parameter settings, and functionality of the PRP network connection.

[0063] Minor events will be logged in an event log and online diagnostic summary, and a diagnostic message will be sent by the enabled service manager 630 to alert the user using the communication unit 608 along the NTW 108. Alerting the user may include alerting (e.g., notifying) the user via a dashboard, mobile phone, user interface, or report. For example, the warning message may be provided (e.g., displayed and / or presented) to a remote operator (e.g., an expert, user technician) at an associated operator station 110 connected to the network 108. Once alerted, the technician will repair the fault in the PRP network. However, the embodiments of the present disclosure are not limited to this. For example, the diagnostic message may be provided to any person and / or entity responsible for diagnosing, repairing and / or resolving anomalies associated with the automation system, and / or any person and / or entity responsible for diagnosing and / or improving the operation of the field automation system.

[0064] In some embodiments, the diagnostic message reported by the enabled service manager 630 may include parameters (e.g., field parameters) and diagnostic data associated with the control system 100 associated with the PRP network connecting node 1 and node 2. The field parameters may include information associated with the control system 100, such as the system configuration. The collected diagnostic data may include information related to the parameter set. For an emergency failure, such as, for example, detecting that there is no PRP network between node 1 and node 2, the enabled service manager 630 will send a diagnostic message to the operator station 110 that an alternative network path between node 1 and node 2 has been activated and that an immediate repair of the PRP network must be performed.

[0065] When the PRP network is repaired, each PRP interface module 502, 504 generates and sends a message that LAN A and LAN B have resumed normal operation to the diagnostic layer 506 of each PRP interface module 502, 504. The processor 500 instructs the PRP interface 509 to resume normal operation, thereby routing message traffic through the PRP interface 509 and LAN A and LAN B. The normal operation message is also sent to the controller 202, thereby notifying the controller 202 that normal operation of LAN A and LAN B has been resumed. Then, the manager 630 generates and records an event to indicate that the PRP network between node 1 and node 2 has resumed normal and sends a message of the normal status of the PRP network to the user.

[0066] In some embodiments, the various functions described in this patent document are implemented or supported by a computer program, which is formed by a computer-readable program code and is embodied in a computer-readable medium. The phrase "computer-readable program code" includes any type of computer code, including source code, object code and executable code. The phrase "computer-readable medium" includes any type of medium that can be accessed by a computer, such as a read-only memory (ROM), a random access memory (RAM), a hard drive, a compact disc (CD), a digital video disc (DVD) or any other type of memory. "Non-transient" computer-readable medium excludes wired, wireless, optical or other communication links that transmit instantaneous electrical signals or other signals. Non-transient computer-readable medium includes a medium that can permanently store data and a medium that can store and rewrite data afterwards, such as a rewritable optical disc or an erasable memory device.

[0067] It may be advantageous to set forth the definitions of certain words and phrases used throughout this patent document. The terms "application" and "program" refer to one or more computer programs, software components, instruction sets, processes, functions, objects, classes, instances, related data or a portion thereof that are suitable for implementation with suitable computer code (including source code, object code or executable code). The term "communication" and its derivatives cover both direct communication and indirect communication. The terms "include" and "comprise" and their derivatives mean including but not limited to this. The term "or" is inclusive, meaning and / or. The phrase "associated with..." and its derivatives may mean including, included within, interconnected with, included within, connected to or connected with, coupled to or coupled with, communicable with, collaborate with, interlace, juxtapose, close to, coupled to or coupled with, have, have the property of, have a relationship with, or have a relationship with. When used with a list of items, the phrase "at least one of..." means that different combinations of one or more of the listed items may be used, and only one item in the list may be required. For example, “at least one of A, B, and C” includes any combination of A, B, C, A and B, A and C, B and C, and A, B, and C.

[0068] The description in this application should not be construed as implying that any particular element, step, or function is an essential or critical element that must be included within the scope of the claims. The scope of subject matter protected by a patent is limited only by the claims as allowed. In addition, none of the claims is intended to invoke 35 U.S.C. §112(f) with respect to any of the appended claims or claim elements, unless the exact words "means for..." or "step for..." followed by a participle phrase identifying the function are expressly used in a particular claim. The use of terms such as (but not limited to) "mechanism", "module", "device", "unit", "component", "element", "member", "device", "machine", "system", "processor" or "controller" within the claims is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 USC §112(f).

[0069] Although the present disclosure has described certain embodiments and generally associated methods, changes and permutations of these embodiments and methods will be apparent to those skilled in the art. Therefore, the above description of the exemplary embodiments does not limit or restrict the present disclosure. Other changes, substitutions and variations are also possible without departing from the spirit and scope of the present disclosure as defined in the following claims.

Claims

1. An apparatus for sending and receiving data between a first network node and a second network node over an alternative communication path; the apparatus comprising: a first network, the first network connecting the first network node to the second network node, the first network establishing a first communication path for sending and receiving data between the first network node and the second network node; a second network connecting the second network node to the first network node, the second network establishing a second communication path for sending and receiving data between the first network node and the second network node; a third network, the third network being connected to the first network node and the second network node, the third network forming an alternative network path, the first network, the second network and the third network being disjoint with each other; and A diagnostic program that, when a failure of a communication path in the first network and the second network is detected, enables the alternative network path to send and receive data between the first network node and the second network node.

2. The apparatus of claim 1 , wherein the first network node comprises a first dual attachment node (DANP1) interface module and the second network node comprises a second dual attachment (DANP2) interface module, each of the DANP1 interface module and the DANP2 interface module comprising: a processor that executes operating system instructions including the diagnostic routine; a parallel redundancy protocol (PRP) interface, the PRP interface connecting the first network and the second network to corresponding independent physical ports, establishing the first communication path and the second communication path between the DANP1 interface module and the DANP2 interface module; and A third interface is connected to the third network and the alternative communication path.

3. The apparatus of claim 2, wherein the diagnostic program of each of the DANP1 interface module and the DANP2 interface module tests failures in the first communication path and the second communication path of the communication path of the first network and the communication path of the second network.

4. The apparatus according to claim 3, wherein the diagnostic program of each of the DANP1 interface module and the DANP2 interface module sends a diagnostic message to the processor of each of the DANP1 interface module and the DANP2 interface module along the third network, thereby informing each DANP1 processor and DANP2 processor of the operating status of the first communication path and the second communication path of the first network and the second network.

5. The apparatus according to claim 4, wherein after receiving the diagnostic message of the failure of the first communication path and the second communication path by each of the DANP1 interface module and the DANP2 interface module, the processor stops the transmission and reception of data through the PRP interface of each of the DANP1 interface module and the DANP2 interface module, and instructs the third interface of each of the DANP1 interface module and the DANP2 interface module to send and receive data through the third interface and the alternative communication path.

6. The apparatus of claim 5, wherein the third network is connected to a controller, the controller executing a failure detection diagnostic algorithm, the failure detection diagnostic algorithm receiving the diagnostic status messages sent by the DANP1 interface module and the DANP2 interface module, and forwarding to an operator station a warning message that the alternative network path has been activated and that repairs to the first network and the second network are required.

7. A method for sending and receiving data between a first network node and a second network node using an alternative communication path; the method comprising: establishing a first communication path between the first network node and the second network node, the first communication path sending and receiving data between the first network node and the second network node; establishing a second communication path between the first network node and the second network node, the second communication path sending and receiving data between the first network node and the second network node; establishing a third communication path between the first network node and the second network node, the third communication path forming the alternative communication path, the first communication path, the second communication path and the third communication path being disjoint from one another; as well as The first communication path and the second communication path are tested for network failure, and when a network failure in the first communication path and the second communication path is detected, the alternative communication path is enabled to send and receive data between the first network node and the second network node.

8. The method according to claim 7, comprising: providing a first dual attach node (DANP1) interface module connected to the first network node and a second dual attach node (DANP2) interface module connected to the second network node; executing operating system instructions by a processor including a diagnostic program through each of the DANP1 interface module and the DANP2 interface module; connecting the first communication path and the second communication path to respective independent physical ports of a parallel redundancy protocol (PRP) interface to transmit and receive data between the DANP1 interface module of the first network node and the DANP2 interface module of the second network node; providing a third interface at each of the DANP1 interface module and the DANP2 interface module, the third interface being connected to the alternative communication path; testing the operating status of the first communication path by the diagnostic program of the DANP1 interface module; testing the operating status of the second communication path by the diagnostic program of the DANP2 interface module; as well as Diagnostic messages of the operating status of the first communication path and the second communication path are sent between the DANP1 interface module and the DANP2 interface module using the alternative communication path.

9. The method according to claim 8, wherein the method further comprises: After receiving the diagnostic message of the failure of the first communication path and the second communication path by each of the DANP1 interface module and the DANP2 interface module, instructing by the processor to stop the transmission and reception of data through the PRP interface of each of the DANP1 interface module and the DANP2 interface module; and The processor instructs the third interface of each of the DANP1 interface module and the DANP2 interface module to transmit and receive data through the third interface and the alternative communication path.

10. The method of claim 9, wherein the alternative communication path is connected to a controller, the controller executing a fault detection diagnostic algorithm, the method comprising: The controller receives the diagnostic message sent by the DANP1 interface module and the DANP2 interface module; as well as causing the fault detection diagnosis to send a warning message to an operator station that the alternative communication path between the DANP1 interface and the DANP2 interface has been activated and that the first communication path and the second communication path need to be repaired; as well as After each of the DANP1 interface module and the DANP2 interface module receives diagnostic information indicating that the first communication path and the second communication path are operating normally, the processor instructs to stop the transmission and reception of data through the third interface and to resume the transmission and reception of data through the PRP interface of each of the DANP1 interface module and the DANP2 interface module.

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