Multicore Redundancy for Process Control Device Diversity
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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 efficient interaction with diverse field devices across different networks, using protocols like MODBUS and Ethernet, and maintaining synchronization for seamless failover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple intelligent field devices with different software interfaces, protocols, and drivers are integrated into a single process control system, then the system can control more diverse and advanced devices, but the configuration effort and management complexity increase significantly
Solution Approach 1:
The system divides the control processing into separate virtual devices, each handling specific device types or protocols. This segmentation allows complex device management to be broken down into manageable, isolated units, reducing overall configuration complexity while maintaining support for diverse field devices
Solution Approach 2:
The system creates a universal control architecture where a single process control system can manage multiple types of intelligent field devices through standardized interfaces. The virtual device abstraction layer provides universal functionality that adapts to different device protocols without requiring separate control systems for each device type
2Device complexity
If a single process control device manages all field devices across multiple networks, then the system structure is simplified, but the device becomes a single point of failure and configuration complexity increases
Solution Approach 1:
The control function is segmented into multiple virtual devices running on separate processing cores. Each virtual device manages specific networks or device groups independently. This segmentation distributes the control burden, preventing any single point of failure from taking down the entire system while maintaining a simplified external system structure
Solution Approach 2:
Different processing cores are assigned to handle different networks or device types based on their specific requirements. Each core can be optimized for its specific function, improving reliability through specialized handling while maintaining overall system simplicity through the virtualization layer
3Reliability
If redundant control processing devices are implemented to ensure continuous operation, then system reliability improves, but the configuration effort and system complexity increase
Solution Approach 1:
Redundant control processing devices are merged into a single physical device with multiple virtual devices running on different cores. This combining provides redundancy and continuous operation capability while eliminating the need to configure and manage separate physical redundant devices, reducing configuration effort and system complexity
Solution Approach 2:
The single physical device is designed to perform multiple functions simultaneously - acting as both primary and backup control devices through its virtualized architecture. This multi-functionality provides redundancy benefits without requiring separate dedicated backup hardware, simplifying the overall redundancy configuration
Data Source
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.