Controller Module Orchestration for Flexible Redundancy Deployment
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Solution Overview
Problem
Conventional network control systems lack flexibility in deploying Application Modules (AMs) with a fixed 1:1 ratio to controller platforms, limiting scalability and redundancy management.
Innovation Solution
The introduction of a Controller Application Module Orchestrator (CAMO) enables dynamic deployment of AMs in various ratios (1:1, 1:N, N:N) across controller platforms, utilizing an I/O mesh network for flexible redundancy and resource management, allowing multiple AMs to run on a single platform and rebalancing load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Application Modules are deployed in a fixed 1:1 ratio to controller platforms, then system reliability is maintained through dedicated redundancy, but system flexibility and scalability are limited
Solution Approach 1:
The patent implements dynamic AM deployment where the orchestrator can allocate and reallocate Application Modules across controller platforms based on real-time system state. Instead of fixed 1:1 binding, AMs can be dynamically assigned to any available controller platform, enabling flexible redundancy management while maintaining system reliability through automated failover capabilities.
Solution Approach 2:
The orchestrator provides universal management capabilities that allow a single pool of Application Modules to serve multiple controller platforms. The system can configure AMs to run on single or multiple platforms, providing multi-functional deployment options that adapt to different reliability and scalability requirements without needing dedicated 1:1 mappings.
2Productivity
If additional controller platforms are added to increase system capacity, then handling capability is improved, but hardware cost and system complexity increase
Solution Approach 1:
The patent merges multiple controller platforms into a unified pool managed by the orchestrator. Multiple controller platforms can host shared Application Modules, allowing the system to increase capacity by utilizing existing hardware resources more efficiently rather than requiring dedicated hardware for each additional function.
Solution Approach 2:
The orchestrator enables virtual copying of Application Modules across controller platforms. Instead of requiring physical duplication of hardware resources, the same AM can be instantiated and executed on multiple controller platforms, increasing system capacity without proportional increases in hardware complexity.
3Ease of operation
If Application Modules are dedicated to fixed controller pairs, then redundancy management is simplified, but resource utilization efficiency decreases
Solution Approach 1:
The orchestrator implements feedback mechanisms that continuously monitor controller platform status, AM performance, and system load. Based on this feedback, the orchestrator automatically adjusts AM deployment, migrating AMs between platforms to optimize resource utilization while maintaining redundancy. This automated feedback loop simplifies redundancy management compared to static configurations.
Solution Approach 2:
The system enables self-service redundancy management where the orchestrator automatically handles AM allocation, failover, and recovery without manual intervention. The orchestrator monitors system health and autonomously redistributes AMs across controller platforms to maintain optimal resource utilization and redundancy, eliminating the need for complex manual configuration.
Data Source
AI summary
A network control system within an industrial processing facility (IPF) includes a controller platforms coupled to one another by a private path redundancy network providing a controller pool, each controller platform having at least one controller including computing hardware and a memory. An application module (AM) pool includes a plurality of AMs, wherein the controller platforms are coupled by an input/output mesh network to input/output devices coupled to field devices that are coupled to processing equipment in the IPF. A control application module orchestrator (CAMO) coupled to the plant-wide network is for dynamically deploying the AM's to the controller platforms, wherein the CAMO receives resource consumption attribute data regarding the controller platforms including a pool of available storage in the memory and processing resources available for the computer hardware. Based on the resource consumption attributes, the plurality of AMs are at least partially automatically deployed to the controller platforms.