Multicore Redundancy Control for Process Network Failover
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Solution Overview
Problem
Complexity in controlling and synchronizing advanced, intelligent field devices in industrial process control systems due to varied software interfaces, protocols, and drivers, which increases configuration effort and management complexity.
Innovation Solution
A multicore processing system with primary and shadow control processing devices, each with multiple cores, implementing redundancy schemes to manage communications and ensure seamless failover, allowing control of multiple sets of devices across different networks using a single processing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional single-core controllers are used to control simple field devices, then the system is easy to configure and operate, but the system cannot efficiently handle complex intelligent field devices with multiple protocols and software interfaces
Solution Approach 1:
The controller is divided into multiple independent cores, each capable of handling different communication protocols and device types simultaneously. This segmentation allows the system to manage complex intelligent field devices without increasing overall configuration complexity, as each core independently processes its assigned devices.
Solution Approach 2:
Each core in the multi-core controller is designed with universal capabilities to handle multiple communication protocols and device interfaces. This multi-functionality enables a single controller to manage diverse intelligent field devices without requiring separate specialized controllers for each device type.
2Reliability
If redundant controllers are implemented for failover capability, then system reliability improves, but system complexity and synchronization difficulty increase
Solution Approach 1:
The redundant controller system is segmented into multiple independent cores that can operate autonomously. During normal operation, primary cores handle control tasks while shadow cores remain in standby. This segmentation simplifies synchronization by allowing independent operation of each core, reducing the complexity of maintaining state consistency across redundant systems.
Solution Approach 2:
Shadow cores maintain simplified copies of control state from primary cores for failover purposes. Rather than requiring full bidirectional synchronization, the shadow cores receive periodic state updates and can immediately take over control when needed, reducing synchronization complexity while maintaining reliability.
3Productivity
If multiple separate controllers are used to control different device sets, then each controller can be optimized for its specific devices, but the overall system complexity and management overhead increase
Solution Approach 1:
Multiple controller functions are merged into a single multi-core controller unit. Each core maintains optimized control for specific device types while sharing common resources such as memory, I/O interfaces, and management software. This merging reduces system management complexity by consolidating multiple controllers into one unified system with centralized configuration and monitoring.
Solution Approach 2:
The multi-core controller provides universal functionality to control diverse device sets through a single unified interface. Each core is optimized for specific device types while the overall system presents a consistent management interface, allowing efficient control of multiple device sets without increasing management overhead.
Data Source
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AI summary
A multicore system controls devices in a process control system. A primary control processing device having a primary master core and a primary remote core is configured for controlling communications on a first network among a first plurality of devices. The primary remote core is configured for controlling communications on a second network among a second plurality of devices. A shadow control processing device is coupled to the first and second networks for processing redundant communications among the devices. The shadow control processing device comprises a shadow master core and a shadow remote core. The shadow master core is configured for controlling communications on the first network among the first plurality of devices. The shadow remote core is configured for controlling communications on the second network among the second plurality of devices.