Single Backup PLC for Automation System Redundancy
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Solution Overview
Problem
Current automation systems with programmable logic controllers (PLCs) are cumbersome and expensive due to the need for a backup PLC for each primary PLC, leading to reduced performance when one module fails, and existing solutions either reduce system performance or require all modules to operate simultaneously.
Innovation Solution
An automation system with a single backup PLC that stores and executes the automation applications of all primary PLCs, allowing it to seamlessly replace any failed primary PLC while maintaining the same number of active controllers, using a monitoring link to detect failures and switch applications as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a backup PLC is provided for each primary PLC, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The backup PLC is designed with multi-functionality to execute different automation applications corresponding to different primary PLCs. It stores multiple automation applications in its memory and can switch between them based on which primary PLC has failed, allowing a single backup unit to replace multiple primary units rather than requiring dedicated backup for each primary PLC.
Solution Approach 2:
The invention merges the backup functions for multiple primary PLCs into a single backup PLC unit. Instead of having separate backup units for each primary PLC, the backup PLC consolidates these functions by storing and being able to execute multiple automation applications, thereby reducing the overall number of components in the system.
2Productivity
If all modules operate simultaneously, then system performance is maintained, but the system is amputated by one module when failure occurs
Solution Approach 1:
The backup PLC performs preliminary actions by storing multiple automation applications in its memory before any failure occurs. This pre-positioning of applications allows the backup PLC to immediately take over and execute the appropriate application when a primary PLC fails, without requiring system reconfiguration or performance degradation.
3Device complexity
If a single backup PLC stores multiple applications, then device complexity is reduced, but the challenge of managing multiple automation applications increases
Solution Approach 1:
The system implements feedback mechanisms where the backup PLC receives information about the status of primary PLCs through monitoring links. When a primary PLC fails, the backup PLC is notified and automatically switches to executing the appropriate stored automation application, providing automated management rather than manual intervention for managing multiple applications.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to an automation system made through a communication network and comprising: • - a first and second programmable logic controller (A and B) respectively executing first and second automation applications (app_A and app_B) to respectively control first and second sets of associated input/output modules (E/S A and E/S B), • - a third programmable logic controller (D), comprising storage means storing the first and second automation applications (app_A and app_B) and being arranged to execute the first automation application in order to stand in for the first programmable logic controller (A), or to execute the second automation application in order to stand in for the second programmable logic controller (B).