Gateway Switchover Control for Redundant Field Device Networks
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Solution Overview
Problem
In industrial automation facilities, plant asset management systems fail to maintain reliable access to field devices when the control room switches from a primary communication network to a redundant one, leading to connection termination and loss of information for the management system.
Innovation Solution
A method is implemented using two gateways connected to field devices via different communication networks, with an operating unit that continuously monitors both networks and automatically switches to the active network, ensuring uninterrupted access by using a common driver for communication access and visualization of the currently active network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundant communication network is implemented with main and auxiliary branches, then reliability of control room communication is improved, but plant asset management system access to field devices is lost when switching occurs
Solution Approach 1:
The system segments the communication architecture into distinct control room communication path and management system access path. The control room can switch between main and auxiliary communication branches while the management system maintains continuous access through its dedicated gateway connection, preventing information loss during switchover events.
Solution Approach 2:
A gateway device serves as an intermediary between the management system and field devices. The gateway monitors the communication network status and maintains the management system's access to field devices regardless of control room switchover events, acting as a mediator that isolates the management system from control room communication changes.
2Reliability
If the control room switches to the auxiliary communication network upon detecting a fault, then communication reliability is improved, but the plant asset management system experiences connection termination
Solution Approach 1:
The management system is preliminarily configured with a dedicated gateway connection that is established before any control room switchover events. This preliminary setup ensures that when the control room switches to the auxiliary network, the management system already has an active communication path to field devices, preventing connection termination and maintaining operational productivity.
3Device complexity
If a single communication network is used for both control room and management system, then system complexity is reduced, but reliability is compromised when network switching is required
Solution Approach 1:
The communication network is segmented into separate functional paths: one for control room operations with main/auxiliary redundancy, and another for management system access through a dedicated gateway. This segmentation increases reliability for both functions while keeping the overall structure manageable through clear separation of concerns.
Data Source
AI summary
The present disclosure relates to automation technology. A first gateway is connected via a first communication network to a field device—and a second gateway is connected to the field device via a second communication network. The first and the second gateway are connected to a control unit. The first communication network and the second communication network are connected to a control room. The control room switches over to the other communication network and establishes a communication connection therewith if a problem is detected in the previous communication connection. Communication access to the first gateway is implemented in the control unit, and communication access to the second gateway is implemented in the control unit via a second driver. The control unit continuously analyses the first communication network and the second communication network and in the event of a control room switchover, switches over to the gateway of that network.