Floating Master Controller Redundancy 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 the hardware units.
Innovation Solution
Implementing a floating master controller system where each hardware unit includes both a master controller (MC) and a floating master controller (FMC) application, allowing for automatic coordination and redundancy, enabling the system to switch between active master controller functionality without disrupting operations, and reducing the need for a separate master controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate master controller is used to control multiple hardware units, then centralized control functionality is achieved, but hardware cost and system complexity increase
Solution Approach 1:
The patent combines the master controller functionality with existing hardware units by integrating an FMC application into each hardware unit's processor. This eliminates the need for a separate dedicated master controller, reducing hardware cost and system complexity while maintaining centralized control capabilities through software-based coordination among hardware units.
Solution Approach 2:
Each hardware unit is equipped with both MC and FMC applications, enabling it to function both as a controlled unit and as a potential master controller. This multi-functionality allows any hardware unit to take over master controller responsibilities if needed, providing redundancy and eliminating the need for a dedicated separate controller.
2Adaptability or versatility
If a separate master controller is used to control multiple hardware units, then centralized control functionality is achieved, but hardware cost increases
Solution Approach 1:
The patent merges the master controller functionality with existing hardware units through software integration. The FMC application is installed on each hardware unit's existing processor, eliminating the need to purchase and install a separate dedicated master controller, thereby reducing hardware cost while maintaining centralized control.
Solution Approach 2:
The master controller functionality is copied into each hardware unit through the FMC application. Instead of having one unique master controller, the control logic is replicated across all hardware units, allowing any unit to perform master controller functions and reducing the need for specialized expensive hardware.
3Ease of operation
If a master controller is used to control multiple hardware units, then control coordination is achieved, but system reliability decreases due to single point of failure
Solution Approach 1:
The patent implements preliminary action by pre-configuring each hardware unit with both MC and FMC applications before operation. This preparation ensures that if the current master controller fails, another hardware unit is already ready and capable of immediately taking over, eliminating single point of failure and improving system reliability while maintaining control coordination.
Solution Approach 2:
The system provides beforehand cushioning against master controller failure by implementing redundant FMC applications in each hardware unit. This protective measure ensures that if one master controller fails, the system has pre-positioned backup capabilities in other units, preventing system shutdown and maintaining reliability.
4Reliability
If master controller functionality is distributed across multiple hardware units, then redundancy and reliability improve, but control coordination complexity increases
Solution Approach 1:
The patent uses feedback mechanisms where hardware units continuously monitor each other's status and communicate through standardized protocols. Each unit can detect when another unit is functioning as master controller and can seamlessly transfer roles based on real-time status feedback, simplifying the coordination of distributed redundancy while maintaining high reliability.
Data Source
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.