Multi-Secondary Controller Synchronization for Redundant Automation
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Solution Overview
Problem
Industrial control systems face costly downtime and production losses due to failures, particularly when they are not designed to be fault-tolerant and require manual intervention for redundancy and synchronization, which can lead to vulnerabilities during equipment updates or load balancing.
Innovation Solution
Implementing a redundancy system with multiple concurrent secondary controllers that can back up a primary controller on any node within the automation control system, allowing for seamless load balancing and equipment updates without disrupting synchronization, thus creating a high-availability environment where control applications can float across any hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a 1:1 redundancy system is used to synchronize CPU data in memory, then fault tolerance is improved, but device complexity increases due to dedicated hardware requirements
Solution Approach 1:
The patent implements a redundancy system where any node in the automation control system can serve as a backup to the primary controller, rather than requiring dedicated backup hardware. This universal approach allows any controller to assume the backup role, reducing hardware complexity while maintaining fault tolerance through software-based redundancy management.
Solution Approach 2:
The system divides the redundancy function into independent, modular components where multiple secondary controllers can simultaneously back up the primary controller. Each secondary controller operates as an independent module that can be activated individually, allowing the system to maintain fault tolerance without requiring a complex dedicated backup hardware architecture.
2Stability of the object's composition
If control applications are bound to dedicated hardware, then system stability is improved, but adaptability decreases when equipment updates or load balancing is needed
Solution Approach 1:
The patent implements dynamic redundancy management where secondary controllers can be activated, deactivated, or reassigned based on system needs. This dynamic approach allows control applications to float between different hardware nodes, enabling equipment updates and load balancing while maintaining system stability through automated failover capabilities.
Solution Approach 2:
The system creates virtual copies of the primary controller's functionality across multiple secondary controllers. These software-based copies allow control applications to be replicated and moved between different hardware nodes without being bound to dedicated hardware, enabling flexible equipment updates while maintaining stable operation through redundant copies.
3Adaptability or versatility
If multiple concurrent secondary controllers are implemented, then adaptability is improved for load balancing and updates, but device complexity increases
Solution Approach 1:
The patent implements self-managing secondary controllers that automatically monitor system status, detect failures, and activate backup functions without requiring complex external management. Each secondary controller independently maintains synchronization with the primary controller and can autonomously assume control if needed, reducing the overall system complexity despite having multiple redundancy elements.
Solution Approach 2:
The system dynamically changes operational parameters of secondary controllers based on system needs, such as activation status, synchronization level, and control authority. This parameter-based management allows multiple secondary controllers to coexist with simplified complexity, as their behavior is controlled through software parameters rather than complex hardware configurations.
Data Source
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AI summary
Methods and systems for synchronizing controllers in an automation control system, can involve arranging redundancy elements in an automation control system comprising a group of nodes, wherein the redundancy elements can include one or more primary controllers and a group of concurrent secondary controllers, and wherein a back-up to the primary controller can exist on any node. Such methods and systems can further involve backing-up of the primary controller by the one or more secondary controllers to allow the primary controller to maintain the one or more secondary controllers as a new, alternate secondary controller for a load balancing or an equipment update