Controller Checkpoint Recovery with Structural Data
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Solution Overview
Problem
Industrial control systems face issues during controller restarts, such as 'ghost points' and unresolved control connections, due to the lack of structural information in checkpoint files, leading to inconsistencies in the operator's view and actual control block connections.
Innovation Solution
The method involves obtaining and storing current structural information in checkpoint files, ensuring that only matching configuration and operational data are restored from the files, with features like structural identifiers and flags to prevent incorrect restorations and maintain consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If checkpoint files are used to restore controller configuration and operational parameters, then the controller can be returned to a fully operational state, but structural information about control blocks and their locations is lost, causing ghost points and unresolved connections
Solution Approach 1:
The patent applies preliminary action by capturing structural information about control blocks and their locations at the time of checkpoint creation. This structural data is stored alongside operational parameters, ensuring that when restoration occurs, both the functional state and the structural context are preserved, preventing ghost points and connection errors.
Solution Approach 2:
The patent uses copying by creating a complete duplicate of the controller's state including structural information. The checkpoint file contains not only operational parameters but also a copy of the control block structure definitions and their hierarchical relationships, allowing accurate restoration without information loss.
2Adaptability or versatility
If configuration changes are made to the process controller, then the controller adapts to new operational requirements, but restoring from a previous checkpoint file creates inconsistencies between the operator's view and actual control block connections
Solution Approach 1:
The patent applies preliminary action by recording the structural configuration state at the time of checkpoint creation. When restoration is performed, the system retrieves both operational parameters and structural information, ensuring that the control block hierarchy and connections match the intended configuration, preventing inconsistencies between operator view and actual connections.
Solution Approach 2:
The patent uses feedback by validating that restored structural information is consistent with the current system state. The system checks whether control blocks and their connections exist as expected after restoration, and can detect and report discrepancies such as ghost points or unresolved connections, allowing operators to verify restoration accuracy.
Data Source
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AI summary
This disclosuire relates generally to control systems and more specifically to a method, apparatus and system for recovery of a controller with known-compatible configuration and run- time data.