Controller Power-Down Sequencing for State Retention on Power Loss

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Solution Overview

Problem

Process control systems face challenges in maintaining robustness during power loss, requiring improved reliability in power down sequencing to ensure continued operation post-restoration.

Innovation Solution

Incorporation of power down circuitry with energy storage devices and data storage to capture and store control application state data during power loss, along with predictive maintenance indicators for component degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If power down sequencing is implemented to store control application state data before shutdown, then system reliability during power loss is improved, but device complexity increases due to additional energy storage devices and data storage devices

Engineering Contradiction:

Improvesystem reliability during power lossVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the power down sequencing functionality with existing controller components. The energy storage device and data storage device are integrated into the controller architecture, merging multiple functions (power management, data storage, reliability monitoring) into a unified system rather than adding separate standalone components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The controller is designed with multi-functional components that serve multiple purposes. The energy storage device not only provides power during shutdown but also enables reliability monitoring. The data storage device serves both as backup storage and as a source for generating reliability indicators, reducing the need for dedicated separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of information

If control application state data is captured and stored during power loss, then data retention is improved, but loss of time occurs during the power down sequence

Engineering Contradiction:

Improvedata retentionVSAvoidtime for power down sequence

Core Design Contradiction:

Loss of informationVSLoss of time

Solution Approach 1:

The system performs preliminary actions by continuously maintaining data in a buffer or cache state during normal operation, so that when power loss is detected, the data is already prepared and ready for immediate transfer to non-volatile storage, minimizing the actual data retention time during shutdown.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The power down sequence is optimized to execute critical data storage operations rapidly. The system prioritizes and accelerates the data capture and storage process during power loss, rushing through the essential operations to minimize the time window where data could be lost.

Inventive Principle:

Principle #21Skipping (Rushing through)

3Reliability

If reliability indicators are determined and output to operators, then predictive maintenance capability is improved, but device complexity increases due to additional monitoring and determination circuitry

Engineering Contradiction:

Improvepredictive maintenance capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements feedback mechanisms where the controller continuously monitors the state of energy storage and data storage devices, determines reliability indicators based on this monitored data, and outputs this information to operators. This feedback loop enables predictive maintenance without requiring complex external monitoring systems.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The controller performs self-diagnosis and self-monitoring of its own components (energy storage device and data storage device). The reliability determination circuitry uses built-in sensors and status registers to assess component health, eliminating the need for separate external diagnostic equipment and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances the reliability of process control systems by ensuring data retention and enabling predictive maintenance, thereby maintaining system functionality and operational readiness.

Implementation Method 1

at least one energy storage device configured to store energy for a power down sequence

Methodology Applied

Scientific EffectEnergy storage: Accumulator (energy)

Implementation Method 2

at least one data storage device to store control application state data

Methodology Applied

Scientific EffectData storage: Battery (electricity)

Data Source

PatentUS20250244736A1Power Down Sequencing in Process Control Systems

Publication Date: 2025.07.31 ABB (SCHWEIZ) AG

AI summary

A power down circuitry for a controller of a process control system includes at least one energy storage device configured to store energy for a power down sequence; and at least one data storage device to store control application state data, wherein the power down circuitry is configured to detect power loss and, in response to the detection of power loss, to carry out the power down sequence, wherein the power down sequence comprises obtaining and storing the control application state data in the data storage device, wherein the power down circuitry is further configured to determine at least one reliability indicator for output to an operator of the process control system.