Distributed PLC Module Reassignment for Fault-Tolerant Automation

The patent implements a universal controller architecture where a single controller can perform multiple functions by dynamically loading different control program modules. The controller is designed to execute control programs for different devices and functions by loading appropriate modules from memory, eliminating the need for dedicated redundant controllers for each function. This multi-functional approach allows one controller to replace what would traditionally require multiple specialized controllers.

The system employs dynamic module loading and switching capabilities, allowing control program modules to be loaded, unloaded, and switched during operation. When a controller fails or needs updating, the system can dynamically reload control modules from memory or redistribute them to other controllers without requiring physical hardware replacement. This dynamic adaptability provides reliability without permanent hardware redundancy.

The control program is divided into separate, modular control program modules that can be independently loaded, executed, and managed. Each control unit runs specific modules rather than complete control programs, allowing the system to segment control functions across multiple units. This segmentation enables flexible redistribution of control modules when system changes occur, such as adding or removing control units, without requiring complete system reconfiguration.

The patent introduces a memory system and module management mechanism that acts as an intermediary between control units and control programs. Control modules are stored in memory and can be dynamically allocated to different control units as needed. This intermediary layer simplifies the distribution management by providing a centralized repository from which modules can be efficiently assigned to appropriate control units based on system requirements.

Instead of duplicating physical controller hardware, the system creates software copies of control program modules that can be stored in memory and loaded onto available controllers. When a controller fails, the control functionality is copied to another controller by loading the appropriate modules from memory. This software-based copying provides functional redundancy without requiring duplicate hardware components.

The system allows controllers to be temporarily discarded (failed or removed) without affecting overall system operation, as their control functions are recovered and redistributed to remaining operational controllers. Control modules can be unloaded from failed controllers and recovered/reloaded onto functional controllers, enabling the system to recover from component failures without permanent redundancy.