Ethernet Cache-Coherent Controller Links for Hot-Swappable Industrial Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing distributed controller connection approaches in industrial systems face challenges such as non-hot swappability, disruption during maintenance and upgrades, security risks, increased costs, and decreased electromagnetic compatibility (EMC) robustness.

Innovation Solution

Implementing distributed controller connections using standard Ethernet connections and cache coherency protocols, which are hot swappable, reduce disruptions during maintenance and upgrades, enhance security, lower costs, and improve EMC robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PCIe distributed controller connection is used, then parallel processing capability is enabled, but hot swappability is lost and maintenance causes system disruption

Engineering Contradiction:

Improveparallel processing capabilityVSAvoidhot swappability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent replaces the PCIe mechanical/electrical interconnect system with an Ethernet-based communication system. This substitution enables hot swappability because Ethernet connections support hot plugging and do not require system shutdown for maintenance, while still achieving parallel processing through networked controller communication.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses standard Ethernet infrastructure to provide multiple functions: parallel processing coordination, hot swappable connectivity, firmware update capability, and inter-controller communication. This universal approach eliminates the need for specialized PCIe-based distributed processing architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If customized modules are developed for intercontroller interaction, then distributed processing is enabled, but development cost and complexity increase

Engineering Contradiction:

Improvedistributed processingVSAvoidcustomized module development

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs standard Ethernet technology and protocols that are universally supported across different controllers and platforms. This eliminates the need for customized intercontroller modules, reducing development complexity while maintaining distributed processing capability through standard network communication.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses standard Ethernet communication protocols and interfaces that are already widely implemented and standardized. Rather than creating custom communication protocols and modules, the system copies/leverages existing proven Ethernet infrastructure for distributed controller interaction.

Inventive Principle:

Principle #26Copying

3Speed

If PCIe interconnect is used for distributed controllers, then communication speed is achieved, but EMC robustness decreases due to ground-to-ground connection

Engineering Contradiction:

Improvecommunication speedVSAvoidEMC robustness

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent replaces the PCIe physical interconnect with Ethernet communication infrastructure. Ethernet's differential signaling and isolation capabilities provide superior EMC robustness while maintaining adequate communication speeds for industrial control applications through standardized network protocols.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If distributed controller connection is implemented, then system scalability is improved, but security risks increase due to potential snooping and counterfeiting

Engineering Contradiction:

Improvesystem scalabilityVSAvoidsecurity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces direct PCIe interconnects with Ethernet communication, which provides built-in security features including network authentication, encrypted communication channels, and protocol-level security. This maintains scalability while reducing security vulnerabilities associated with direct physical interconnects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250110478A1Systems and methods of implementing distributed controller connections within industrial systems

Publication Date: 2025.04.03 ROCKWELL AUTOMATION TECH INC

AI summary

Systems and methods for providing distributed controller connections within industrial systems. One system may include an Ethernet physical media configured to facilitate a packetized cache-coherency protocol across a plurality of industrial controllers of an industrial system. The system may also include an industrial personal computer (“IPC”) included in the plurality of industrial controllers, where the IPC may be configured to control at least a first portion of an industrial process of the industrial system. The system may also include a programmable logic controller (“PLC”) included in the plurality of industrial controllers, where the PLC may be directly connected to the PLC with the Ethernet physical media and configured to control at least a second portion of the industrial process of the industrial system.