Distributed Finite State Machine Control for Power Unit Uptime
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power generation unit control systems require downtime for software updates or repairs, leading to potential malfunctions and sub-optimal performance, as they often need to be stopped for maintenance, introducing risks of interruptions in electricity distribution.
Innovation Solution
A distributed finite state machine configuration involving a high-level controller and low-level controllers that cooperate to ensure continuous control of power generation units, allowing the high-level controller to modify its software while the low-level controller maintains operation, seamlessly transitioning control if the high-level controller fails or is taken offline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the controller is stopped for software updates or repairs, then software maintenance can be performed, but power generation unit operation is interrupted and reliability decreases
Solution Approach 1:
The controller is divided into a high-level controller and a low-level controller, each capable of independent operation. The high-level controller handles complex control functions while the low-level controller manages basic operations, allowing one controller to be maintained while the other continues to operate and maintain power generation unit functionality.
Solution Approach 2:
A distributed finite state machine configuration acts as an intermediary framework that coordinates between the high-level and low-level controllers. This configuration enables seamless transition of control functions between controllers, allowing maintenance of one controller without interrupting power generation unit operation.
2Adaptability or versatility
If the controller is stopped for software updates, then software can be updated, but control functionality is lost and performance deteriorates
Solution Approach 1:
The low-level controller is pre-configured with essential control functions and a finite state machine that enables it to take over control immediately if the high-level controller becomes unavailable. This preliminary preparation ensures that control functionality is maintained without interruption during software updates or repairs of either controller.
3Device complexity
If a single controller is used for power generation unit control, then system complexity is reduced, but the system is vulnerable to failures and requires downtime for maintenance
Solution Approach 1:
The controller system is segmented into two independent controllers (high-level and low-level) with distinct functional responsibilities. This segmentation creates redundancy, eliminating the single point of failure vulnerability while maintaining manageable complexity through clear division of control functions.
Solution Approach 2:
The system transitions from a single-controller parameter state to a dual-controller parameter state, changing the operational mode from centralized to distributed control. This parameter change enables failover capability and continuous operation while maintaining system complexity at an acceptable level through standardized controller interfaces.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system includes a high-level controller coupled to a low-level controller for controlling a physical asset. The high-level controller executes a first finite state machine for controlling a power generation unit via a network. The low-level controller executes a second finite state machine that may have fewer states than the first finite state machine. The second finite state machine places the low-level controller in a default mode of operation for controlling the power generation unit under various conditions such as when the high-level controller is controlling the physical asset during a normal mode of operation; when the high-level controller is revising the first finite state machine; when the high-level controller is controlling the physical asset using a revised first finite state machine; and/or upon detecting a loss of communications between the high-level controller and the low-level controller.