Runtime Asset Data Cache Replication for Fast Industrial Failover
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Solution Overview
Problem
Current industrial plant systems face challenges in achieving sub-second failover for client applications due to high client application display callup times and increased costs in active-active configurations, particularly when switching between primary and secondary workstations in server-based architectures.
Innovation Solution
A computer-implemented method and cache management system that distributes runtime asset data among workstations, replicating and updating data locally and remotely across client applications, ensuring high availability and reducing failover times by evaluating data freshness based on value, quality, and timestamp attributes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a serverless architecture is used where client applications fetch runtime data directly from controllers, then hardware and software costs are reduced, but client application display callup time increases to about eight seconds
Solution Approach 1:
The patent implements a server that proactively pushes runtime data to client applications before it is requested. The server maintains a data cache and automatically sends data updates to clients, eliminating the need for clients to fetch data on demand. This preliminary action reduces display callup time from eight seconds to under one second while maintaining the serverless architecture's cost advantages.
2Loss of time
If an active-active configuration with multiple operations workstations is used, then client application display callup time is reduced to under one second, but failover time increases and additional hardware and software licenses are needed
Solution Approach 1:
The patent introduces a server as an intermediary between controllers and client applications. This server handles data caching, processing, and push notifications to multiple clients simultaneously. By using this intermediary, the system achieves fast display callup times without requiring multiple active operations workstations, thus reducing hardware and software license requirements while maintaining high availability.
3Device complexity
If an active-passive configuration is used with a primary and secondary operations workstation, then hardware and software costs are reduced, but failover time increases
Solution Approach 1:
The server maintains a ready-to-use data cache that can immediately serve multiple client applications. When a workstation fails, the server can instantly push cached data to alternative clients without requiring them to fetch data from controllers. This preliminary preparation of data in the server's cache enables sub-second failover, improving reliability while maintaining the simpler active-passive workstation configuration.
Data Source
AI summary
A method is provided for managing availability of runtime asset data used by client applications hosted on workstations of an industrial system, the method including distributing runtime asset data about assets of the industrial system received at the plurality of workstations among runtime asset data caches associated with the client applications. At least a portion of locally stored runtime asset data stored on a local runtime asset data cache is replicated and stored remotely on the runtime asset data cache associated with another client application. The locally stored runtime asset data is periodically evaluated to determine if it is up-to-date, and in response to determining it is not up-to-date, the locally stored runtime asset data is updated by requesting and retrieving a replicated and updated version of the locally stored runtime asset data from the runtime asset data cache remotely storing the replicated version.