Controller Task Synchronization for Hardware-Free High Availability

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Solution Overview

Problem

Conventional high availability schemes for controllers are platform- and application-specific, costly, and require dedicated hardware, making them unsuitable for low-cost controllers that need to maintain high availability across different domains and support open standard communication protocols.

Innovation Solution

An application programming interface for state and data synchronization between power and process domains, allowing retrofitting of existing simplex controllers to achieve high availability without hardware modifications, using a dedicated communication channel for synchronization and enabling any controller with spare interfaces to synchronize application tasks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional high availability schemes are implemented, then reliability is improved, but device complexity and cost increase due to dedicated hardware interfaces

Engineering Contradiction:

Improvehigh availabilityVSAvoidhardware interfaces

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies universality by creating a platform- and application-agnostic synchronization interface that can be used across different controller types and domains. The synchronization manager provides a universal mechanism for state synchronization that works with various communication protocols (IEC 61850, DCS protocols) and controller platforms, eliminating the need for dedicated hardware interfaces for each specific high availability implementation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces the mechanical/dedicated hardware interface approach with a software-based synchronization manager that uses existing communication channels. Instead of requiring physical dedicated hardware interfaces for high availability, the system uses software synchronization protocols transmitted through standard communication interfaces, substituting mechanical hardware requirements with software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If platform- and application-specific high availability schemes are used, then reliability is improved, but adaptability deteriorates

Engineering Contradiction:

Improvehigh availabilityVSAvoidplatform compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The synchronization manager is designed as a universal interface that operates across multiple platforms and applications without requiring platform-specific implementations. It supports both power domain (IEC 61850) and process domain (DCS) controllers, providing consistent high availability functionality across different domains through a single standardized interface.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the high availability functionality into a separate, modular synchronization manager component that can be independently implemented and configured. This segmentation allows the same synchronization mechanism to be applied across different platforms and applications without coupling the high availability functionality to specific platform implementations.

Inventive Principle:

Principle #1Segmentation

3Reliability

If dedicated hardware interfaces are required for high availability, then reliability is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvehigh availabilityVSAvoidcontroller production

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the need for dedicated hardware interfaces by substituting them with software-based synchronization mechanisms. The synchronization manager uses existing communication interfaces and protocols to achieve high availability, removing the manufacturing complexity associated with designing and producing dedicated hardware interfaces for each controller.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

By creating a universal synchronization interface that works across different controller types and communication protocols, the system allows existing controllers to be upgraded to high availability mode through software configuration alone, without requiring hardware modifications or specialized manufacturing processes for different controller variants.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4235417A1Synch manager for high availability controller

Publication Date: 2023.08.30 SCHNEIDER ELECTRIC SYSTEMS USA INC

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AI summary

A synchronization manager interface determines a first state of execution of an application task executing on a first controller at defined synchronization points and further determines a second state of execution of the application task executing on a second controller at the defined synchronization points. The synchronization manager interface, when executed, configures the first controller to transmit the first state from the first controller to the second controller via a communications channel established between the controllers for verifying a successful synchronization of the application task on the controllers based on a comparison of the first state with the second state.