Floating Master Controller Failover for Multi-Unit Hardware Control
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Solution Overview
Problem
Existing master controller systems for controlling multiple hardware units, such as compressors and pumps, are costly, complex, and prone to failure, leading to system degradation or complete shutdown if the master controller fails or loses connection with hardware units.
Innovation Solution
Implementing a floating master controller system where each hardware unit includes a processor configured with both master controller and floating master controller applications, allowing for automatic coordination and redundancy, enabling the system to switch between operating modes (master, backup, tracking, and fault modes) and maintain functionality even if the primary master controller fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single master controller is used to control multiple hardware units, then the system structure is simple and cost-effective, but the system reliability deteriorates because the master controller may fail or lose connection with hardware units
Solution Approach 1:
The patent divides the master controller functionality into multiple independent controller units distributed across different hardware units. Each controller unit can independently function as a master controller, segmenting the centralized control function into distributed segments that can operate autonomously if needed.
Solution Approach 2:
The patent implements preliminary action by having backup controller units ready in advance to take over master controller functions. The system pre-configures multiple potential master controllers and establishes failover protocols before any failure occurs, ensuring continuous operation.
2Reliability
If redundancy is added to prevent master controller failure, then system reliability improves, but hardware costs and system complexity increase
Solution Approach 1:
The patent makes each controller unit universal by enabling it to perform both slave controller functions and master controller functions. Each hardware unit contains a controller that can adapt its role based on system needs, eliminating the need for dedicated master and slave hardware and reducing overall system complexity.
Solution Approach 2:
The system implements self-service through automatic failover mechanisms where controller units autonomously detect master controller failures and transfer control authority without external intervention. The controllers monitor system status and automatically reconfigure themselves to maintain operation.
3Loss of time
If automatic failover is implemented, then system downtime is reduced, but the coordination complexity between controller units increases
Solution Approach 1:
The patent implements feedback mechanisms where controller units continuously monitor system status, master controller health, and communication links. This real-time feedback enables automatic detection of failures and triggers appropriate failover actions, reducing downtime through rapid response to system changes.
Data Source
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AI summary
A floating master controller system is provided that includes a plurality of hardware units, each capable of carrying out at least one mechanical function. Each hardware unit includes a processor configured via controller code included in a memory to cause the respective hardware unit to operate and carry out the at least one mechanical function. The controller code for each hardware unit includes a master controller (MC) application and at least one floating master controller (FMC) application. Each MC application is operably configured to function as an active master controller that controls the at least one mechanical function in each of the plurality of hardware units in the system and is operably configured to control the at least one mechanical function for its respective hardware unit responsive to tracking another one of the MC applications that is functioning as the active master controller in the system. Also, the at least one FMC application for each hardware unit is operably configured to automatically coordinate with each other FMC application to move active master controller functionality for the system between each of the different MC applications in the system.