Distributed Controller Ethernet Links for Hot-Swappable Industrial Control
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Solution Overview
Problem
Existing distributed controller connection approaches in industrial systems face challenges such as non-hot swappability, disruption during maintenance and upgrades, security risks, increased costs, and decreased electromagnetic compatibility (EMC) robustness.
Innovation Solution
Implementing distributed controller connections using standard Ethernet connections and cache coherency protocols, which allows for hot swapping, reduces disruptions during maintenance and upgrades, enhances security, lowers costs, and improves EMC robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If PCIe is used for distributed controller connection, then high-speed communication is achieved, but hot swappability is lost and system disruption occurs during maintenance
Solution Approach 1:
The patent replaces the PCIe mechanical/electrical interconnect system with an Ethernet-based communication system. This substitution allows controllers to maintain high-speed communication while enabling hot swappability, as Ethernet connections can be established and terminated without powering down the system, unlike PCIe which requires system shutdown for controller replacement.
Solution Approach 2:
The patent implements a universal Ethernet interface that can serve multiple functions: high-speed data communication, cache coherency maintenance, and hot plugging support. This single interface replaces the specialized PCIe connection, providing multi-functionality while resolving the contradiction between speed and ease of operation.
2Adaptability or versatility
If PCIe is used for distributed controller connection, then distributed task execution is enabled, but electromagnetic compatibility robustness decreases
Solution Approach 1:
The patent substitutes the PCIe physical interconnect with Ethernet communication, which uses differential signaling and shielding that provides superior electromagnetic compatibility. This replacement maintains distributed processing capability while reducing susceptibility to electromagnetic interference and ground loops.
3Adaptability or versatility
If customized modules are developed for controller integration, then controller interaction is enabled, but development cost and complexity increase
Solution Approach 1:
The patent adopts a universal Ethernet interface that eliminates the need for customized communication modules for each controller type. Standard Ethernet protocols and cache coherency mechanisms enable different controller types to interoperate without requiring proprietary integration hardware or software, significantly reducing development complexity and cost.
Solution Approach 2:
The patent changes the communication parameter from specialized PCIe protocols to standard Ethernet protocols, allowing controllers to interact using universally supported communication standards. This parameter change eliminates the need for customized modules while maintaining full controller interoperation capability.
4Adaptability or versatility
If independent firmware upgrades are performed, then system flexibility is improved, but system disruption occurs
Solution Approach 1:
The patent implements Ethernet-based communication that maintains continuous controller interaction during firmware upgrades. Unlike PCIe where upgrading one controller requires system shutdown, the Ethernet architecture allows controllers to be upgraded independently while maintaining communication links, ensuring continuous operation and eliminating system disruption.
Data Source
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AI summary
Systems and methods for providing distributed controller connections within industrial systems. One system may include an Ethernet physical media configured to facilitate a packetized cache-coherency protocol across a plurality of industrial controllers of an industrial system. The system may also include an industrial personal computer ("IPC") included in the plurality of industrial controllers, where the IPC may be configured to control at least a first portion of an industrial process of the industrial system. The system may also include a programmable logic controller ("PLC") included in the plurality of industrial controllers, where the PLC may be directly connected to the PLC with the Ethernet physical media and configured to control at least a second portion of the industrial process of the industrial system.