Hot Cutover Box for Seamless Controller Migration

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Solution Overview

Problem

Current methods for migrating a final control element from one controller to another in industrial process control systems often disrupt the operating variable, requiring cumbersome manual adjustments and verbal communication, or allow no adjustments at all during the migration process.

Innovation Solution

The development of a hot cutover box that uses a combination of milli-ammeters, connectors, and electronic circuits to create an electronic virtual bypass, allowing seamless migration of control signals without disrupting electrical continuity, and employing software to verify and match signal parameters before switching, thereby enabling a bumpless and efficient cutover process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If block and bypass valves are used for controller migration, then manual control capability is maintained during migration, but the process requires cumbersome verbal communication and manual adjustments

Engineering Contradiction:

Improvemanual control capabilityVSAvoidvalve configuration complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

A hot cutover box is introduced as an intermediary device between the process controller and final control element. This box contains a dual-gang relay that can switch control signals between old and new controllers, eliminating the need for manual valve operations while maintaining seamless control transition capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical valve-based control system is replaced with an electronic switching system using a dual-gang relay in the hot cutover box. This substitution eliminates mechanical adjustments and verbal communication requirements by automatically managing the control signal transition through electrical switching

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If pneumatic boondoggle is used for controller migration, then control signal continuity is maintained, but the system requires complex pneumatic configuration and verbal communication

Engineering Contradiction:

Improvecontrol signal continuityVSAvoidpneumatic configuration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pneumatic boondoggle system is replaced with an electronic hot cutover box containing a dual-gang relay. This electronic substitution maintains control signal continuity more reliably while eliminating complex pneumatic tubing, fittings, and manual valve adjustments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hot cutover box serves as an intermediary that bridges old and new controllers through electronic switching. The dual-gang relay internally manages the transition, providing continuous control signals without requiring external pneumatic configurations or manual interventions

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If mechanical stem clamp is used for controller migration, then control signal stability is maintained, but no adjustments can be made during migration

Engineering Contradiction:

Improvecontrol signal stabilityVSAvoidadjustment capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The static mechanical clamp system is replaced with a dynamic electronic switching system. The dual-gang relay in the hot cutover box can be electronically controlled to switch between old and new controllers, providing both signal stability during switching and adaptability for adjustments during the migration process

Inventive Principle:

Principle #15Dynamics

4Productivity

If traditional hot cutover methods are used, then controller migration can be performed, but the process takes significant time and disrupts the operating variable

Engineering Contradiction:

Improvemigration speedVSAvoidprocess continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The hot cutover box maintains continuous control signaling to the final control element throughout the migration process. The dual-gang relay ensures that at all times, whether during switching or adjustment, the final control element receives uninterrupted control signals, eliminating disruptions to operating variables while enabling rapid migration

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The hot cutover box is pre-configured with both old and new controller connections before migration begins. The dual-gang relay is pre-wired to accept signals from either controller, allowing instantaneous switching without interruption to the controlled process, thereby achieving both speed and reliability

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10353367B2Hot cutover box

Publication Date: 2019.07.16 CUTOVERS INC

AI summary

The disclosed hot cutover box creates an electronic virtual bypass around a terminal strip to which existing control system, new control system, and final control element connections may be made, thereby allowing migration from an existing to a new control system to take place. Sensors allow measurement of a current signal without disrupting electrical continuity and connectors allow the hot cutover box to be introduced to the circuit with no disruption to the controller output. Once the hot cutover box is in place, wiring connections can be removed from the terminal strip as the hot cutover box effectively provides a parallel current pathway around the terminal strip.