Field Device Access Routing for Controller Hot Switching
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Solution Overview
Problem
Existing process control systems require system shutdown for replacing controller hardware, as the combination of field devices, I/O nodes, controllers, and control applications is fixed and cannot be changed during operation.
Innovation Solution
A control system comprising field devices, a first control apparatus with an access route controller, a second control apparatus with an access route controller, and a network for communication between them, allowing the access route controllers to work together to control the input/output route to the field devices, enabling switching between control applications without stopping the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the combination of field device, I/O node, controller, and control application is fixed for operation, then system stability is maintained, but system shutdown is required when replacing controller hardware
Solution Approach 1:
The system is segmented into multiple control apparatuses (first control apparatus and second control apparatus), each capable of independently controlling the field device. This segmentation allows the control function to be distributed across multiple units, enabling seamless switching when one apparatus needs maintenance or replacement, thus eliminating system downtime while maintaining stability.
Solution Approach 2:
Multiple control apparatuses are configured with universal control capabilities, where each apparatus can function as the primary controller for the field device. The access route controllers in both apparatuses are designed to work together, allowing either apparatus to take over control operations, providing multi-functionality and eliminating the need for system shutdown during hardware replacement.
2Adaptability or versatility
If control application is migrated to another control apparatus, then hardware replacement is enabled, but access route control complexity increases
Solution Approach 1:
Access route controllers are introduced as intermediary components in both control apparatuses to manage the input/output routes between control applications and field devices. These intermediaries abstract the complexity of route management, enabling seamless control application migration between apparatuses while maintaining manageable system complexity through standardized interface control.
Data Source
AI summary
A control system includes at least one field device, a first control apparatus, a second control apparatus, and a network. The first control apparatus has a first field device, included among the one or more field devices, directly connected thereto and includes a first access route controller and a first control application capable of controlling the first field device. The second control apparatus includes a second access route controller and a second control application capable of controlling the first field device. The first access route controller and the second access route controller are configured to work together to control an input/output route from the first control application and the second control application to the first field device.