Controller Backup Across Different Hardware Architectures

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Solution Overview

Problem

Conventional process control systems with a fixed 1:1 ratio of controller platforms to application modules lack flexibility and are limited in scalability and hardware compatibility, restricting the deployment of application modules to a single hardware architecture.

Innovation Solution

Implementing a controller application module orchestrator (CAMO) that dynamically deploys application modules (AMs) across multiple controller platforms, allowing flexible ratios and enabling deployment on controllers with different hardware architectures, including PowerQUICC/ARM and X86 architectures, through state and value translation and synchronization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed 1:1 ratio of controller platforms to application modules is used, then hardware architecture compatibility is simplified, but system scalability and flexibility are reduced

Engineering Contradiction:

Improvesystem scalabilityVSAvoidhardware architecture compatibility

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system segments the controller platform and application module relationship by introducing virtualization. The controller platform is divided into virtual machine instances, allowing multiple AMs to be hosted on a single physical controller. This segmentation enables flexible scaling while maintaining hardware compatibility through standardized virtual interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller platform is designed with multi-functionality to host multiple application modules simultaneously through virtualization. A single physical controller can serve multiple AMs by creating virtual machine instances, making the hardware universally applicable to different control scenarios without requiring dedicated hardware for each AM.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If multiple application modules are deployed on a single controller platform, then system scalability is improved, but hardware resource contention and system complexity increase

Engineering Contradiction:

Improvesystem scalabilityVSAvoidhardware resource management

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system implements nested virtualization where virtual machine instances are nested within the physical controller platform. Each VM instance can host one or more application modules, creating a hierarchical structure that efficiently manages hardware resources while supporting multiple AMs on a single controller.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A virtualization layer acts as an intermediary between the physical hardware and multiple application modules. This intermediary manages resource allocation, isolation, and coordination, allowing multiple AMs to run on a single controller without direct hardware conflicts while simplifying resource management.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If controllers with different hardware architectures are supported, then system versatility is improved, but state synchronization and compatibility challenges arise

Engineering Contradiction:

Improvehardware architecture compatibilityVSAvoidstate synchronization

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system changes the parameter of hardware architecture compatibility by introducing architecture-agnostic virtual machine interfaces. The virtualization layer abstracts hardware-specific parameters, allowing AMs to run on different hardware architectures (PowerQUICC/ARM or X86) without modification, while maintaining reliable state synchronization through standardized communication protocols.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If redundant controller platforms are deployed, then system reliability is improved, but hardware cost and system complexity increase

Engineering Contradiction:

Improvesystem availabilityVSAvoidhardware resources

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The system merges multiple application modules onto a single physical controller platform through virtualization. This consolidation allows redundant controller configurations to support more AMs with fewer physical hardware resources, reducing overall system complexity and hardware costs while maintaining high availability through redundancy.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3889781B1Process control system with different hardware architecture controller backup

Publication Date: 2025.07.23 HONEYWELL INTERNATIONAL INC

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AI summary

A process control system includes first type and second type controllers having different hardware architectures coupled together by a redundancy network for providing a controller pool. Primary application modules (AMs) are coupled to the controller platforms by a plant-wide network. The controller platforms are coupled by an input/output (I/O) mesh network to I/O devices to provide an I/O pool coupled to field devices coupled to processing equipment. A translating device translates states and values from one of the primary AMs running on a first type controller to generate a backup AM having an instruction set compatible with the second type controller. A controller application module orchestrator (CAMO) extends synchronization to the second type controller, makes the backup AM available to the second type controller, and then switches to utilize the second type controller as an active controller running the process.