Dual-Processor Control Switching for Downtime-Free Software Updates
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Solution Overview
Problem
Existing software updates for industrial equipment require downtime, necessitating a stop in operations.
Innovation Solution
A control system with a first processor using first software for continuous control and a second processor using updated software, managed by a switching manager to ensure seamless transition without downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If software update is performed by stopping equipment operation, then software can be updated reliably, but equipment downtime increases and productivity decreases
Solution Approach 1:
The control device is divided into multiple processors (first processor and second processor) that can operate independently. The first processor handles control during the current control period while the second processor prepares for and takes over in the next control period, enabling continuous operation during software updates.
Solution Approach 2:
The second processor loads and prepares the updated software in advance during the current control period before the switch occurs. This preliminary action ensures that the software update is ready to take effect immediately when the control period transitions, avoiding any downtime.
2Productivity
If software update is performed without stopping equipment, then productivity is maintained, but control stability and reliability may deteriorate
Solution Approach 1:
The control device operates in discrete control periods with a clear boundary between the current control period and the next control period. The switch from the first processor to the second processor occurs precisely at this boundary, ensuring that control actions are completed in one period before transitioning to the next period with updated software.
Solution Approach 2:
The switching manager acts as an intermediary that coordinates the transition between processors. It manages the handover of control information and ensures that the switch occurs at the appropriate timing, maintaining control stability during the transition.
3Productivity
If processor switching is implemented for continuous control, then equipment can operate without downtime, but system complexity increases
Solution Approach 1:
Both the first processor and the second processor are designed with the same control capability and can independently execute control algorithms for the next control period. This universality allows either processor to take over without requiring specialized design, simplifying the switching mechanism.
Solution Approach 2:
The second processor creates a copy of the control algorithm and control information from the first processor. This copying approach allows the second processor to prepare control actions in advance without requiring complex real-time synchronization mechanisms during the switch.
Data Source
AI summary
According to the present embodiment, a control device comprises a first processor, a switching manager, and a second processor. The first processor is configured to execute control of a next control period on basis of control information having been changed during a current control period. The switching manager is configured to transmit to the first processor a switching notification for instructing switching to the first processor. The second processor is configured to use second software different from first software to be capable of executing control of a device by repeating a predetermined control period. The second processor uses at least the changed control information before a switching completion time as a time point where a currently processing control period ends to start control of the device in a next control period when control of the device in the next control period is executable.