Controller Fail-Safe Logic Transfer for Industrial Error States
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Solution Overview
Problem
Existing industrial installations face downtime due to controller devices entering an error state, affecting the functioning of field devices and requiring efficient and cost-effective management solutions.
Innovation Solution
A method and system utilizing a processing unit to analyze program execution parameters, identify error states in controller devices, apply fail-safe logic, and transfer control to non-error state devices, thereby maintaining operation and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a controller device enters an error state, then the controller device halts execution of the engineering program, but the functioning of field devices controlled by the controller device is hampered resulting in downtime
Solution Approach 1:
The system performs preliminary actions by detecting error states in controller devices before they cause complete system failure. The processing unit continuously monitors program execution parameters and identifies error conditions, allowing the system to initiate fail-safe logic and transfer control to backup controller devices proactively, thereby preventing downtime in the industrial plant.
Solution Approach 2:
The processing unit acts as an intermediary that receives program execution parameters from controller devices, analyzes them to detect error states, and coordinates the fail-safe response. This intermediary function enables the system to bridge the gap between error detection and the execution of fail-safe logic, ensuring continuous operation of field devices even when a controller device fails.
2Productivity
If fail-safe logic is transferred to a non-error state controller device, then continuous operation is maintained, but system complexity increases due to multiple controller devices and error state management
Solution Approach 1:
Multiple controller devices are designed with universal functionality, where each controller device can execute the same engineering program and control the same field devices. This multi-functionality enables seamless failover, as any non-error state controller device can take over control when another device enters an error state, maintaining continuous operation without requiring specialized backup hardware.
Solution Approach 2:
The processing unit continuously receives program execution parameters from controller devices and provides feedback about their operational status. This feedback mechanism enables real-time error state detection and triggers the fail-safe logic transfer process. The systematic monitoring and feedback loop simplify the management of multiple controller devices by providing automated status tracking and decision-making based on objective performance data.
Data Source
AI summary
A method and system for a technical installation during occurrence of an error state in a controller device of the technical installation is provided. The method includes receiving, by a processing unit, a plurality of program execution parameters from each of a plurality of controller devices in the technical installation. The method further includes determining, an error state in a first controller device of the plurality of controller devices. The method further includes determining from a plurality of fail-safe logic, a fail-safe logic associated with the first controller device based on the determination of the error state in the first controller device. The method further includes initiating, by the processing unit, an execution of the fail-safe logic associated with the first controller device, in a second controller device of the plurality of controller devices.