ECC Memory Diagnosis and Restart Control for Power Plant Reliability
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Solution Overview
Problem
Current ECC memory systems in control devices for electric power generation plants cannot predictably detect permanent defects, leading to uncorrectable errors that can cause system failure without warning, necessitating unplanned shutdowns and potential damage.
Innovation Solution
A control device with memory diagnosis and error correction mechanisms that detect correctable and uncorrectable errors, differentiate between soft and permanent defects, and implement restarts and system switching to prevent accumulation of uncorrectable errors, including features like power-on status management, error logging, and system switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ECC memory is used to automatically correct errors, then error correction capability is improved, but permanent defects cannot be detected and accumulate leading to uncorrectable errors
Solution Approach 1:
The system performs preliminary actions by detecting and logging errors at the time they occur, rather than waiting for them to accumulate into uncorrectable states. The error logging function records each error event with timestamps and locations, enabling proactive maintenance before permanent defects develop
Solution Approach 2:
The system implements feedback mechanisms through continuous monitoring of error patterns. By analyzing logged error data, the system can identify trends and predict when permanent defects may develop, providing feedback that triggers maintenance actions before uncorrectable errors occur
2Reliability
If error correction is performed continuously, then data reliability is improved, but system complexity increases due to multiple diagnosis and restart mechanisms
Solution Approach 1:
The control system is segmented into distinct functional modules: error detection unit, error logging unit, diagnosis unit, and restart control unit. Each module handles specific tasks independently, making the overall complex system manageable through modular design and clear separation of concerns
Solution Approach 2:
An error log serves as an intermediary data structure between error detection and diagnosis/restart actions. The log accumulates error information over time, allowing the diagnosis unit to analyze patterns without requiring continuous direct interaction between detection and correction mechanisms, thus simplifying control flow
3Reliability
If the system restarts on error detection, then error accumulation is prevented, but operational time is lost due to repeated restarts
Solution Approach 1:
The system applies partial action by restarting only for specific types of errors that indicate serious problems, while allowing operation to continue for minor correctable errors. The diagnosis unit evaluates error patterns and determines whether restart is necessary, avoiding excessive restarts that would waste operational time
Solution Approach 2:
The system performs preliminary diagnosis and evaluation of error patterns before deciding to restart. By analyzing logged errors and determining whether they indicate permanent defects or temporary issues, the system can make informed decisions about when restart is necessary, minimizing unnecessary operational interruptions
Data Source
AI summary
A control device includes: memory diagnosis means for setting a power-on status when an electric power is turned on and diagnosing an ECC memory; restarting means for restarting the control device when the memory diagnosis means detects a correctable error of the ECC memory during the power-on status of the ECC memory; and operation processing means for resetting the power-on status and performing a normal operation when the memory diagnosis means does not detect a correctable error of the ECC memory, while performing the normal operation when a correctable error of the ECC memory is detected because of the restart of the control device by soft reset after the reset of the power-on status but when the control device is not in the power-on status.