HMI Tag Switching During Hot Cutover Migration
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Solution Overview
Problem
The existing automation systems face challenges in efficiently migrating from an old system to a new one, particularly during hot cutover processes, where the mixing of I/O and functional blocks from both systems can lead to prolonged tag assignment changes, increased risk of human error, and potential plant shutdowns.
Innovation Solution
An information providing system that includes a control device and a managing device. The managing device has an acquiring unit to receive tag information from both the existing and new systems, a change notification unit to detect changes in effective tags, and notifies the control device. The control device then changes the access destination for the effective tags to the new system based on the detection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tag assignment changes are performed during hot cutover migration, then system migration can be completed, but the migration time is prolonged and plant shutdown becomes unavoidable
Solution Approach 1:
The system performs automatic tag assignment changes without requiring operator intervention. The HMI automatically detects tag mappings between old and new systems, performs the switching, and updates displays autonomously, eliminating the need for manual reassignment during hot cutover migration
Solution Approach 2:
The patent replaces manual mechanical operations (operators physically changing tag assignments) with an automated information processing system that electronically detects, switches, and updates tag mappings, thereby reducing migration time while maintaining continuous plant operation
2Reliability
If operators review diagrams and perform risk assessments during hot cutover, then safety can be maintained, but human error increases due to operating multiple HMIs
Solution Approach 1:
The HMI acts as an intermediary that automatically manages tag assignments between the old and new control systems. Instead of operators directly manipulating multiple systems, the HMI mediates the transition by automatically detecting tag mappings and switching assignments, thereby reducing human error while maintaining safety
Solution Approach 2:
The system performs self-verification and risk management automatically. The HMI detects potential issues during tag switching and manages the migration process autonomously, eliminating the need for operators to manually review diagrams and perform risk assessments across multiple interfaces
3Adaptability or versatility
If tag assignment changes are performed manually during migration, then system transition can be achieved, but the likelihood of human error increases leading to plant shutdown
Solution Approach 1:
The patent replaces manual tag assignment operations with automated electronic detection and switching. The HMI automatically identifies tag mappings between systems and performs the switching electronically, eliminating manual errors while maintaining the ability to transition between old and new control systems
Solution Approach 2:
The system automatically detects tag mappings and performs self-verification during migration. The HMI monitors the transition process, automatically updates tag assignments, and verifies successful switching, thereby reducing human error while maintaining system adaptability
Data Source
AI summary
An information providing system includes a control device and a managing device. The managing device includes an acquiring unit that receives first tag information regarding a first tag set to a first component of a first controller from a first system, and receives second tag information regarding a second tag set to a second component of a second controller from a second system and a change notification unit that detects whether an effective tag has changed from the first tag to the second tag based on the first tag information and the second tag information, and that notifies the control device of a detection result. The control device includes a setting change unit that changes an access destination to the effective tag to the second controller based on the detection result.