Host Controller Orchestration for Redundant Broadcast Reduction
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Solution Overview
Problem
Conventional process control systems with a controller HIVE arrangement face inefficiencies due to unnecessary network synchronization traffic and redundant database updates, where a single event triggers broadcast messages from all host controllers, and multiple events result in multiple redundant updates across the network.
Innovation Solution
Implementing a single online orchestrator program that coordinates a shared database across multiple host controllers, where only the master controller broadcasts updates, and each host controller fetches and applies incremental changes to maintain synchronization, reducing redundant message processing and improving database synchronization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all host controllers broadcast database updates simultaneously in response to a single event, then database synchronization is achieved across the network, but network traffic and computational overhead increase significantly
Solution Approach 1:
The patent introduces a coordinator host controller that acts as an intermediary between external events and the host controller network. When an external event occurs, the coordinator single-threadedly processes the event and generates a single database update message, which is then broadcast to all host controllers. This mediator approach ensures database synchronization while eliminating the redundant broadcast traffic that would occur if all host controllers independently detected and responded to the same event.
2Reliability
If all host controllers independently detect and respond to external events, then database updates are propagated across the network, but redundant message processing occurs
Solution Approach 1:
The coordinator host controller serves as a central intermediary that consolidates external event detection and processing. Instead of each host controller independently detecting events and generating updates, the coordinator single-threadedly processes external events and generates a single authoritative update message. This reduces the complexity of message processing across the network, as all host controllers receive and process only the necessary updates from the coordinator rather than filtering out redundant messages from multiple sources.
3Reliability
If multiple host controllers broadcast updates for multiple simultaneous events, then database changes are propagated, but network traffic multiplies exponentially
Solution Approach 1:
The coordinator host controller acts as a central mediator that processes multiple simultaneous external events in a single-threaded manner. When multiple events occur, the coordinator sequentially processes each event through its event processing logic, generating a single consolidated set of database update messages. This prevents the exponential multiplication of broadcast messages that would occur if each host controller independently processed and broadcast updates for each event, thereby reducing the quantity of broadcast traffic while maintaining database synchronization.
4Speed
If host controllers use multi-threaded event processing, then response time to external events is reduced, but database synchronization consistency deteriorates
Solution Approach 1:
The patent segments the event processing responsibilities by separating the coordinator host controller's single-threaded event processing from the distributed database synchronization across multiple host controllers. The coordinator handles external event detection and processing in a single thread to ensure consistency, while the network broadcast and local database updates at each host controller can proceed in parallel. This segmentation maintains database consistency through the coordinator's sequential processing while achieving speed improvements through the parallel distribution of updates across the network.
Data Source
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AI summary
A method of process control in a PCS. The PCS provides host controllers coupled together, I/O devices, field devices, and processing equipment, configured together to run a process, the plurality of host controllers having stored a single online orchestrator program for coordinating a shared and synchronized database for the host controllers, wherein the online orchestrator program uses and tracks currently available host controllers and selected control programs for controlling the process. The PCS also includes an offline orchestrator. The orchestrator software is run on the currently available host controllers that shares and synchronizes the initial shared database version to the currently available host controllers. A selected host controller responsive to an event broadcasts updated shared database version to the currently available host controllers. The offline orchestrator accepts commands relating to a deployment/undeployment of control program(s) among the currently running host controllers in response to changing requirement(s) by the control programs or an outside environment.