Automation Device State Image Reproduction
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Solution Overview
Problem
Current methods for debugging and error identification in automation devices are limited, as they cannot record all variables and their changes, making it difficult to reproduce the sequence of a control program and assess product quality over time.
Innovation Solution
A method and arrangement that allow the automation device to create images of its internal state at any point in time, storing them in a backup memory, enabling the backup device to reproduce the program sequence by processing these images and releases, allowing for complete traceability and analysis of past events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If trace mechanisms are used to record process data, then error detection capability is improved, but complete traceability of all variables and their changes cannot be achieved
Solution Approach 1:
The patent creates a complete copy of the automation device's internal state at specific points in time by generating images of all relevant data (process images) and storing them in backup memory. This copying approach enables complete traceability of all variables and their changes, resolving the limitation of conventional trace mechanisms that cannot record all data.
Solution Approach 2:
The system performs preliminary actions by continuously creating and storing backup images of the automation device's state during normal operation. These pre-recorded images are then used for later reproduction and analysis, enabling complete traceability without requiring continuous recording of all data streams.
2Reliability
If all process data is archived for complete traceability, then product quality assessment is improved, but data storage requirements and system complexity increase
Solution Approach 1:
The patent segments the data archiving system into discrete time-point snapshots (process images) rather than continuous recording. Each image captures the complete state at a specific moment, allowing selective storage and reproduction of only necessary data points, thereby reducing overall system complexity while maintaining traceability.
Solution Approach 2:
Instead of archiving all continuous data streams, the system creates selective copies of the device state at predetermined intervals. This copying strategy reduces storage requirements and system complexity while still enabling complete quality assessment when needed.
3Productivity
If the backup device processes the control program asynchronously, then reproduction speed is improved, but synchronization with the original program sequence may be lost
Solution Approach 1:
The patent introduces process images as intermediary data structures that capture the complete state at specific points in time. These images serve as mediators between the original program execution and the backup reproduction, allowing asynchronous processing while maintaining sequence accuracy through the use of release indicators that mark specific reproduction points.
Solution Approach 2:
The system performs preliminary actions by pre-capturing complete device states in process images during normal operation. These pre-captured images enable the backup device to reproduce the program sequence asynchronously without losing accuracy, as all necessary state information is already recorded at the required precision points.
Data Source
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AI summary
The invention relates to a method for replaying the execution of a program (P1) of an automation device (AG) intended for process control, wherein a program (P2) corresponding to the program (P1) of the automation device (AG) with regard to process control is provided for processing by means of a backup device (BG). By suitable means, the complete history of the automation device (AG) can be mapped and the execution of the program (P1) can be replayed. This makes it possible to subsequently and repeatedly access any point in the past with regard to the processing of the program (P1) and to replay all associated data.