Integrated Backup Control Hardware for Fault Tolerant Systems
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Solution Overview
Problem
Existing electronic control systems lack effective redundancy and fault tolerance, particularly in handling non-gross failures and channel-wide failures, where primary controls may malfunction undetected or experience gross errors, leading to potential device damage without adequate protection or backup.
Innovation Solution
A dual-channel electronic control configuration with primary and secondary controls, where secondary controls assume protection and backup roles, enabling redundancy and fault tolerance by communicating via a serial data bus and utilizing dual-coil solenoid windings, allowing protection/backup controls to intervene in case of primary control failures, and enabling backup control without an external dedicated unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate protection and backup control systems are used, then fault coverage is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines separate protection control and backup control functions into a single integrated control unit. This unit contains multiple control channels that can operate in different modes (normal, protection, backup) depending on the failure condition detected. By merging these functions, the system achieves comprehensive fault coverage while reducing the number of separate hardware components, thereby lowering complexity and cost.
Solution Approach 2:
The integrated control unit is designed to perform multiple functions: normal control, protection control, and backup control. The control unit can dynamically switch between these functions based on the operational status and failure conditions detected by its multiple channels. This multi-functionality eliminates the need for separate dedicated protection and backup systems.
2Reliability
If dedicated external backup control is implemented, then backup reliability is improved, but system cost and complexity increase
Solution Approach 1:
The patent integrates backup control functionality within the same control unit that performs normal and protection control. The control unit contains multiple channels (e.g., first control channel, second control channel) that can assume backup roles depending on failure conditions. This eliminates the need for a separate external backup control system while maintaining backup reliability.
3Reliability
If multiple separate control systems are used for redundancy, then fault tolerance is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple control functions and redundancy mechanisms into a single integrated control unit with multiple internal channels. This approach achieves the fault tolerance of multiple separate systems while reducing manufacturing costs by eliminating the need to produce, assemble, and maintain multiple separate control units.
Solution Approach 2:
The control unit is designed as a universal platform that can perform normal control, protection control, and backup control functions. This multi-functionality reduces manufacturing complexity and cost compared to producing separate specialized control systems for each function.
4Object-affected harmful factors
If comprehensive protection and backup mechanisms are added, then device safety is improved, but control system complexity increases
Solution Approach 1:
The patent merges protection and backup control functions into a single integrated unit with multiple channels. This unit can detect failures and switch between normal, protection, and backup modes internally, providing comprehensive device safety without requiring multiple separate control systems that would increase overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures continuous device operation by detecting and mitigating primary control failures, preventing damage through integrated protection and backup mechanisms, enhancing fault tolerance and eliminating the need for external backup controls.
Implementation Method 1
The control device includes first and second primary controls and first and second protection/backup controls that utilize dual-coil solenoid windings
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
An electronic control configuration (10a) includes at least one secondary microprocessor (32a, 32b) operable to control a device (12). The at least one secondary microprocessor (32a, 32b) assumes protection control of the device responsive to a first type of failure by transmitting a protection control signal to a first effector (18). The at least one secondary microprocessor (32a, 32b) assumes backup control of the device responsive to a second type of failure by transmitting a backup control signal to a second effector (16). The backup control functionality of the at least one secondary microprocessor (32a, 32b) can be selectively disabled.