Dual-Processing Pump Controller for Secure Remote Monitoring
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Solution Overview
Problem
Existing pump systems face inefficiencies in operation and security risks due to direct internet connectivity, which can lead to manipulation and data corruption, necessitating improved control and data management with enhanced security and reliability.
Innovation Solution
A dual-processing unit controller is implemented, with a first deterministic processing unit for low-level, time-critical operations and a second processing unit for high-level, complex tasks, ensuring separation from external networks and introducing redundancy to enhance security and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pumps are connected to external networks for data collection and remote monitoring, then data accessibility and remote monitoring capability are improved, but security risk and vulnerability to manipulation increase
Solution Approach 1:
The controller is divided into two separate processing units: a first processing unit that provides low-level services directly to pumps, and a second processing unit that provides high-level services and connects to external networks. This segmentation isolates the critical control functions from network connectivity, allowing remote monitoring while preventing direct network access to pump control, thereby addressing both remote monitoring capability and security risk
Solution Approach 2:
The second processing unit acts as an intermediary between external networks and the pump system. It handles all network communications, data collection, and remote monitoring functions, while the first processing unit handles direct pump control. This intermediary structure enables remote monitoring capability while protecting the core control system from direct network exposure and potential security threats
2Device complexity
If a single processing unit is used for all control tasks, then device complexity is reduced, but reliability and security against system-wide failures decrease
Solution Approach 1:
The controller is segmented into two independent processing units with distinct functions: the first processing unit dedicated to low-level pump control and the second processing unit dedicated to high-level services and network communication. This segmentation reduces the risk of system-wide failures by isolating critical control functions from non-critical services, thereby improving operational reliability while maintaining manageable complexity
Solution Approach 2:
Each processing unit is optimized for its specific function: the first processing unit is tailored for deterministic, time-critical low-level control tasks, while the second processing unit handles complex high-level services and network communications. This local optimization ensures that each unit operates with appropriate resources and priorities, improving overall system reliability without excessive complexity
3Manufacturing precision
If deterministic response time is ensured for low-level services, then control precision and reliability are improved, but device complexity increases due to separate processing units
Solution Approach 1:
The control system is segmented into two processing units where the first processing unit is dedicated exclusively to deterministic low-level control tasks requiring precise timing, while the second processing unit handles non-deterministic high-level services. This segmentation ensures control precision for critical functions while containing complexity within modular, functionally-separated units
Data Source
Figure 1
AI summary
Pump system with at least one pump, in particular a vacuum pump or a compressor, a controller connected to the at least one pump, wherein the controller comprises: a first processing unit directly connected to the at least one pump for providing low level services to the at least one pump, and a second processing unit connected to the first processing unit to provide high level services to the pump system, wherein the second processing unit is connectable to an external network.