Three-Subsystem Automation Redundancy With Split Synchronization Clocks
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Solution Overview
Problem
Conventional redundant automation systems face challenges in maintaining high availability during system failures, as they require identical hardware and firmware versions, leading to temporary singular operation and extended downtime, especially when replacing faulty components.
Innovation Solution
A redundantly configured automation system with multiple subsystems, where each subprogram and its associated submemory have distinct synchronization clocks, allowing for flexible synchronization and dynamic assignment of redundancy partners, enabling subprogram-granular redundancy and compatibility with different firmware versions, and allowing for cloud-based implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional redundant automation systems use identical hardware and firmware versions for both subsystems, then system reliability is improved through complete synchronization, but system adaptability deteriorates because replacement requires exact matching versions, leading to extended downtime
Solution Approach 1:
The patent segments the automation system into multiple independent subsystems (at least three subsystems) where each subsystem can operate autonomously. This segmentation allows different firmware versions to coexist in different subsystems, eliminating the requirement for identical versions across all subsystems while maintaining system reliability through redundancy.
Solution Approach 2:
The patent implements dynamic assignment of redundancy partners, where subsystems can dynamically switch between different redundancy configurations. This dynamic approach allows the system to adapt to different firmware versions by重新assigning which subsystem serves as the backup for which active subsystem, thereby improving both reliability and adaptability.
2Reliability
If conventional redundant systems require complete system replacement upon failure, then system reliability is maintained through identical redundancy, but loss of time increases due to warehouse retrieval and installation delays
Solution Approach 1:
The patent maintains at least three subsystems in a ready state, where the third subsystem can immediately assume the role of redundancy partner if either the first or second subsystem fails. This preliminary preparation of additional subsystems eliminates the need for warehouse retrieval and installation delays, as a replacement subsystem is already available and synchronized.
Solution Approach 2:
The patent changes the redundancy parameter from fixed pairwise redundancy to flexible multi-subsystem redundancy. This allows the system to dynamically adjust which subsystems are active and which are in standby mode, enabling faster failover by having pre-synchronized subsystems ready to take over immediately upon failure.
3Device complexity
If conventional systems use fixed assignment of redundancy partners, then synchronization is simplified, but system complexity increases when dealing with failures and planned retrofits due to singular operation requirements
Solution Approach 1:
The patent implements dynamic redundancy partner assignment where subsystems can switch roles between active and standby modes. This dynamic configuration allows the system to maintain optimal synchronization relationships while facilitating easier maintenance operations, as subsystems can be taken offline and brought back online without requiring complete system shutdown or complex reconfiguration.
Solution Approach 2:
The patent makes each subsystem universal by enabling any subsystem to serve as a redundancy partner for any other subsystem. This multi-functionality allows flexible role assignment during maintenance operations, where any healthy subsystem can take over the redundancy role, simplifying maintenance procedures and improving ease of operation during retrofits and repairs.
Data Source
AI summary
Method for operating a redundantly configured automation system which includes has a first subsystem, a second subsystem and a third subsystem, wherein a sequence program is implemented in each of the subsystems of the automation system and is executable in a runtime environment to fulfill automation tasks, and wherein a data memory is implemented in the subsystems in each of the automation systems, where the sequence program includes at least a first subprogram and a second subprogram, the data memory in each of the subsystems includes at least a first submemory and a second submemory, the first subprogram and the first submemory are synchronized with a first synchronization clock between the first and second subsystems, and the second subprogram and the second submemory are synchronized with a second synchronization clock between the first and third subsystems, and where the first and synchronization clocks differ from one another.