Multi-Level Controller System for Power Generation Unit Maintenance
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Solution Overview
Problem
Conventional power generation unit controller systems require downtime for software updates or repairs, leading to potential malfunctions and sub-optimal performance, which can disrupt electricity distribution and are costly.
Innovation Solution
A multi-level controller system comprising a high-level controller, a surrogate computing element, and a low-level controller, where the high-level controller generates supplementary signals to create a second version of control software for the low-level controller, allowing for flexible and continuous operation of the power generation unit even during high-level controller downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If software updates or repairs are performed on the controller, then software reliability is improved, but normal operations must be stopped causing productivity loss and potential performance degradation
Solution Approach 1:
The controller is divided into multiple independent controller elements (first controller element, second controller element, third controller element) that can operate autonomously. This segmentation allows one element to be updated or repaired while others continue normal operations, eliminating the need to stop productivity for software maintenance.
Solution Approach 2:
A surrogate controller element is prepared in advance with updated or repaired software versions. Before switching to the surrogate element, the system ensures it is ready and validated. This preliminary preparation allows seamless transition without interrupting ongoing operations, maintaining both reliability improvement and continuous productivity.
2Ease of repair
If the controller is taken offline for software maintenance, then software can be updated or repaired, but the power generation unit may malfunction or perform sub-optimally
Solution Approach 1:
Multiple controller elements are merged into a single controller system that functions as one unified control unit. The controller elements work together in parallel, with each capable of performing the full range of control functions. This merging allows the system to maintain complete operational capability even when individual elements are being maintained, ensuring both ease of repair and continuous reliable performance.
Solution Approach 2:
A surrogate controller element acts as an intermediary during software maintenance operations. When one controller element needs updating or repair, the surrogate element temporarily assumes its responsibilities, mediating the transition and ensuring continuous proper control of the power generation unit without performance degradation.
3Productivity
If multiple controller elements are used to enable continuous operation, then productivity is maintained during maintenance, but device complexity increases
Solution Approach 1:
Each controller element is designed to be universal and multi-functional, capable of performing all necessary control functions independently. This universality means that any single controller element can take over the entire control workload, reducing the need for complex specialized configurations and simplifying the overall system architecture while maintaining continuous operation capability.
Solution Approach 2:
The controller elements are designed to be homogeneous in their capabilities and interface requirements. Each element has identical functional capabilities and communication interfaces, which simplifies the system architecture by eliminating the need for complex heterogeneous integration. This homogeneity allows any element to replace any other, maintaining productivity while reducing device complexity through standardized design.
Data Source
AI summary
Exemplary embodiments described in this disclosure pertain to a system that includes a high-level controller coupled to a low-level controller in an arrangement that allows the high-level controller to cooperate with the low-level controller for controlling a power generation unit. The high-level controller generates supplementary signals and/or supplementary code that is provided to a surrogate controller. The surrogate controller uses the supplementary signals and/or supplementary code to generate control software that is provided to the low-level controller for controlling certain operational aspects of the power generation unit that cannot be independently controlled by the low-level controller. If the high-level controller is placed in an independent mode of operation for any reason, the surrogate controller continues to cooperate with the low-level controller for controlling various operations of the power generation unit that were being controlled by the low-level controller prior to the high-level controller entering the independent mode of operation.