Network Combiner Splitter Redundant Controller MAC Address
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Solution Overview
Problem
Existing process control systems in industrial environments require complex and costly redundancy setups for reliable operation, involving multiple controllers and additional ports, which can be cumbersome and expensive, especially in high-temperature environments like glass manufacturing or oil refineries.
Innovation Solution
An electronic combiner/splitter device that connects multiple redundant controllers to a higher-tier control system using a single medium access control (MAC) address, allowing communication between the controllers and the system through PHY chips, which adapt timing and strip embedded clock signals, thereby simplifying the system design and reducing the need for additional ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple redundant controllers are connected to a control system using traditional methods, then system reliability is improved, but device complexity and cost increase due to requiring additional ports
Solution Approach 1:
The patent combines multiple controller connections into a single port interface. The combiner device merges multiple redundant controller signals into one interface that connects to the control system, eliminating the need for separate ports for each controller and reducing overall device complexity while maintaining reliability through redundancy
Solution Approach 2:
The single port interface on the combiner device serves multiple functions by handling connections to multiple redundant controllers simultaneously. This multi-functional interface replaces what would traditionally require multiple dedicated ports, reducing complexity while supporting the same reliability requirements
2Reliability
If multiple redundant controllers are connected using traditional methods, then system reliability is improved, but the number of required ports increases leading to higher costs
Solution Approach 1:
The combiner device merges multiple controller connections into a single physical port interface. Multiple redundant controllers are connected to the combiner, which then presents a single interface to the control system, thereby reducing the quantity of ports required from multiple to one while preserving system reliability
3Reliability
If PHY chips are used to adapt timing and strip embedded clock signals, then communication reliability between redundant controllers is improved, but device complexity increases
Solution Approach 1:
The PHY chip acts as an intermediary component between the redundant controllers and the combiner device. It performs essential functions of timing adaptation and clock signal extraction, ensuring reliable communication while being integrated into the overall simplified architecture, thus the complexity increase is localized and justified by the communication reliability gains
Data Source
AI summary
In a network coupling redundant controllers to a control system, an electronic device is provided. The device comprises a first interface coupled to the control system addressed using a unique medium access control (MAC) address, a second interface coupled to a first redundant controller, and a third interface coupled to a second redundant controller. The device receives a first message via the first interface and transmits the first message via the second interface and via the third interface. The device receives a second message via the second interface and transmits the second message via the first interface. The device receives a third message via the third interface and transmits the third message via the first interface.