Container-Based Control Execution for Legacy-Compatible High Availability
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Solution Overview
Problem
Industrial process control and automation systems face challenges in upgrading components while maintaining compatibility with legacy technology, especially in distributed control systems where upgraded controllers need to work harmoniously with legacy controllers for redundancy and high availability.
Innovation Solution
A high availability industrial control system utilizing a container-based architecture with nodes supporting container platforms, a high availability management network for failure detection and redistribution of containers, and connectivity through primary and secondary control networks and I/O networks, allowing for seamless integration of upgraded and legacy controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If upgraded controllers are introduced into the system, then system performance and functionality are improved, but compatibility with legacy controllers becomes problematic
Solution Approach 1:
The controller is divided into separate software modules (legacy module and upgraded module) that can operate independently within the same hardware platform. This segmentation allows upgraded functionality to coexist with legacy compatibility through modular architecture.
Solution Approach 2:
A container-based virtualization layer acts as an intermediary between upgraded and legacy controllers. The container management system orchestrates communication and resource allocation, enabling heterogeneous controllers to work together harmoniously without direct compatibility requirements.
2Reliability
If redundancy is implemented to improve availability, then system reliability is improved, but system complexity increases
Solution Approach 1:
The container management system automatically performs failure detection, container redistribution, and failover operations without manual intervention. This self-service capability handles redundancy management autonomously, reducing the operational complexity despite the presence of redundant components.
Solution Approach 2:
The system dynamically adjusts container placement and redundancy configuration based on real-time node availability and capacity. Containers can be automatically redistributed across different nodes as conditions change, providing adaptive redundancy that optimizes reliability while minimizing static complexity.
3Reliability
If container redistribution is performed to maintain availability, then system reliability is improved, but system downtime increases
Solution Approach 1:
Secondary containers are pre-configured and maintained in standby positions across the network before failures occur. When a node fails, these pre-positioned containers can immediately assume primary roles without requiring time-consuming redistribution or recreation operations.
Solution Approach 2:
The system maintains continuous control functionality by keeping secondary containers active and synchronized even during normal operation. This ensures that failover can occur instantly when needed, eliminating service interruption and maintaining uninterrupted control of the controlled object.
Data Source
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AI summary
In an industrial automation system, a control device adapted to a container-based architecture has been developed. The control device may comprise one or more containers instantiated with control execution application, communication application, and or redundancy management application.