Cloud Controller State Synchronization for Seamless Physical Control Failover
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In industrial cloud control scenarios, managing state transitions during failures in cloud infrastructure can lead to inconsistencies in cyber-physical systems, potentially causing efficiency or safety violations.
Innovation Solution
A computer-implemented method and system that involves running at least two instances of a logical control function on a controller node, synchronizing their internal states, and providing consistent control instructions to physical entities, thereby ensuring seamless failover without introducing inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple replicated controller instances are deployed in cloud infrastructure for reliability, then system availability is improved, but state consistency between instances deteriorates over time
Solution Approach 1:
The system performs preliminary state synchronization before failover occurs by continuously synchronizing internal states between controller instances. The primary controller proactively pushes state updates to secondary controllers, ensuring that when failover is needed, the standby controller already has current state information, preventing state inconsistency during transition.
Solution Approach 2:
The system implements feedback mechanisms where controller instances report their state to a central coordination service or to each other. This feedback loop allows the system to detect state divergence and trigger synchronization operations, ensuring that all instances maintain consistent state information while providing redundant control capability.
2Reliability
If monolithic controller application is replicated for cloud resilience, then failover capability is improved, but development flexibility and scalability deteriorate
Solution Approach 1:
The patent segments the monolithic controller application into multiple independent control functions or microservices that can be replicated and deployed independently. Each control function can be developed, deployed, and scaled separately while maintaining coordinated operation through the state synchronization mechanism, providing both resilience and development flexibility.
Solution Approach 2:
The system creates a universal controller architecture where multiple controller instances can serve different purposes - some as primary controllers for specific devices, others as standby or backup controllers. This multi-functional design allows the same controller software to be deployed in various roles, improving both reliability and adaptability to different deployment scenarios.
3Productivity
If controller instances operate independently in cloud environment, then deployment scalability is improved, but control consistency during failure deteriorates
Solution Approach 1:
The system introduces an intermediary coordination service or message queue that mediates communication between independently deployed controller instances. This intermediary enables state synchronization and coordination without requiring direct peer-to-peer communication, allowing controllers to be deployed independently while maintaining control consistency through the mediating coordination layer.
Data Source
AI summary
Methods and Nodes for Controlling a Physical Entity A method (100) is disclosed for controlling a physical entity. The method is performed by a controller node running at least two instances of a logical control function. The method comprises receiving over an input mechanism node input data relating to the physical entity (110) and providing, to each of the at least two instances of the control function, instance input data generated from the node input data. The method further comprises causing at least one of the instances to process the received instance input data and generate instance output data, and providing, over an output mechanism, instance output data from at least one of the instances of the control function, wherein the output mechanism is operably connected to the physical entity. The method further comprising synchronizing an internal state of each of the at least two instances of the control function.