Modular Backplane Switching for Fault-Tolerant Industrial Controllers
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Solution Overview
Problem
Industrial controllers with linear backplanes face communication disruptions when a module is removed or fails, and redundant configurations increase hardware and installation costs, while offering limited scalability and flexibility for upgrades.
Innovation Solution
A modular industrial controller with a backplane that maintains communication between modules using embedded switches and local circuits, allowing for flexible configuration and easy upgrades by connecting bases with complementary connectors and optional cable extensions between rows of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a linear backplane configuration is used, then communication between adjacent modules is simplified, but communication is disrupted when a module is removed or fails
Solution Approach 1:
The backplane is segmented into multiple independent communication paths between modules. Each module has separate communication interfaces that can operate independently, allowing data to be routed through alternative segments when one path is blocked by a failed or removed module.
Solution Approach 2:
The communication architecture transitions from a one-dimensional linear chain to a two-dimensional mesh-like structure. Modules can communicate not only with adjacent modules but also through multiple routing dimensions, providing alternative paths when direct adjacent communication is interrupted.
2Reliability
If redundant devices and communication busses are configured, then operational reliability and safety rating are improved, but hardware expense and installation cost increase
Solution Approach 1:
Each module is designed with universal communication capabilities that can function in both redundant and non-redundant configurations. The same module hardware can adapt to different system requirements through software configuration, eliminating the need for separate redundant hardware components.
Solution Approach 2:
The communication topology is dynamic and can be reconfigured based on system needs. Modules can dynamically switch between single-path and multi-path communication modes, allowing the system to provide redundancy when needed while maintaining simplicity when not required.
3Reliability
If redundant configuration is implemented, then safety rating is improved, but upgrade flexibility is reduced
Solution Approach 1:
The system is divided into independent, interchangeable module segments. Each module can be individually upgraded or replaced without affecting the entire system architecture, allowing flexible upgrades while maintaining the redundant communication paths required for safety ratings.
Solution Approach 2:
The system allows parameter changes in communication protocols and routing configurations without requiring hardware changes. This enables upgrades and adaptations while maintaining the redundant infrastructure needed for safety certifications.
Data Source
AI summary
An industrial controller with a modular backplane includes multiple modules, where each module includes a base and a chassis. Electrical connectors located on each side of the base engage the base of an adjacent module such that the bases are electrically connected. The backplane is defined by and extends through each of the bases connected to each other. A chassis is inserted into each base. Each chassis includes an embedded switch and a local circuit. The embedded switch is in communication with the base, and the local circuit performs the operation of the corresponding module. The embedded switch receives data transmitted along the backplane between bases. The embedded switch reads the data intended for the module and passes the data to the local circuit for further processing. Similarly, the embedded switch receives data from the local circuit and inserts the data on the backplane for transmission to the appropriate module.