Access Route Control for Hot-Swappable Hardware Controllers
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Solution Overview
Problem
Existing control systems require system shutdown for replacing controller hardware, and they incur excessive communication and processing loads when accessing field devices via networks, limiting flexibility and efficiency in hardware replacement and load distribution.
Innovation Solution
A control system architecture that includes field devices, access route controllers, and a cache server to distribute processing load and enable seamless hardware replacement by routing input/output instructions through a network, allowing for abstract access methods and optimal access method selection based on control types and load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If controller hardware is replaced in a traditional control system, then hardware maintenance and upgrades can be performed, but the system must be shut down causing production loss
Solution Approach 1:
The control system is segmented into multiple independent control apparatuses (first control apparatus and second control apparatus), each capable of independently controlling field devices. This segmentation allows one control apparatus to take over while another is being replaced, enabling hot-swapping of hardware without system shutdown.
Solution Approach 2:
The system dynamically changes the operational state parameters of control apparatuses by switching between active and standby modes. The first access route controller and second access route controller can change their operational parameters to redirect I/O instructions to the appropriate active control apparatus, enabling seamless hardware replacement.
2Speed
If field devices are accessed directly by control applications on the same controller, then communication speed is fast, but the control application becomes dependent on specific hardware making replacement difficult
Solution Approach 1:
An access route controller is introduced as an intermediary between control applications and field devices. The access route controller receives I/O instructions from control applications, determines the appropriate routing path, and executes the access. This intermediary layer enables control applications to access field devices through multiple possible routes (direct connection or network), providing hardware independence while maintaining communication efficiency.
Solution Approach 2:
The access route controller provides multiple access methods (direct access and network access) for controlling field devices. This multi-functionality allows the system to adapt to different hardware configurations and enables flexible hardware replacement without affecting control application functionality.
3Adaptability or versatility
If control applications access field devices through network connections, then hardware flexibility is improved, but communication load and processing time increase
Solution Approach 1:
The access route controller dynamically selects the optimal access method based on real-time conditions. When a control application needs to access a field device, the access route controller determines whether to use direct access (faster) or network access (more flexible), dynamically adjusting the routing path to balance speed and flexibility requirements.
Solution Approach 2:
The access route controller pre-establishes multiple access paths and routing rules before actual I/O operations occur. By preparing routing configurations in advance and maintaining readiness for both direct and network access modes, the system minimizes access time when hardware flexibility is required, reducing the time penalty associated with network-based access.
Data Source
AI summary
A control system includes at least one field device, a first control apparatus, a second control apparatus, a cache server, and a network. The first control apparatus has a first field device directly connected thereto and includes a first access route controller and a first control application capable of controlling the first field device. The second control apparatus includes a second access route controller and a second control application capable of controlling the first field device. The cache server includes a memory and a third access route controller. The first through third access route controllers are configured to work together to be capable of transferring, to the cache server, an input/output instruction for the first field device from the second control application.