Network Control Device Synchronization Failure Detection
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Solution Overview
Problem
In networks with redundant control devices, synchronization failures can lead to undefined states and conflicts, especially when both control devices attempt to take over simultaneously, risking damage to production plants, and existing solutions increase manufacturing overhead with redundant synchronization designs.
Innovation Solution
A method where each control device alternates between active and idle states regarding peripheral devices, with active devices sending synchronization and activity signals, allowing the idle device to determine if the active device has failed, thus preventing simultaneous activation and eliminating the need for redundant synchronization designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant synchronization devices and synchronization lines are provided between control devices, then reliability of control takeover is improved, but manufacturing overhead and system complexity increase
Solution Approach 1:
The patent extracts the failure detection function from the synchronization mechanism itself. Instead of relying solely on synchronization signal presence to detect failures, the system separately monitors synchronization signal reception at each control device. This separation allows the system to detect synchronization failures without requiring redundant synchronization infrastructure.
Solution Approach 2:
The patent implements feedback by having each control device monitor whether it receives synchronization signals from the other control device. This self-monitoring feedback mechanism enables each device to independently detect synchronization failures and make informed decisions about control takeover, eliminating the need for additional redundant synchronization components.
2Productivity
If the backup control device attempts to take over when synchronization fails, then control availability is improved, but conflicting control signals may be sent causing system damage
Solution Approach 1:
The patent applies preliminary action by having control devices pre-determine their operational state based on synchronization signal monitoring before any failure occurs. Each device continuously checks whether it receives synchronization signals and prepares appropriate takeover actions only when both synchronization failure and active device failure are confirmed, preventing premature or conflicting takeover attempts.
Solution Approach 2:
The patent implements preliminary anti-action by preventing the backup control device from attempting takeover when only synchronization fails. The system proactively blocks potential conflicting control signals by requiring confirmation that the active device has actually failed before allowing takeover, thus preventing the harmful effect of simultaneous control attempts.
3Measurement precision
If synchronization monitoring is enhanced to detect active device failure, then accuracy of failure detection is improved, but additional synchronization infrastructure is required
Solution Approach 1:
The patent applies self-service by having each control device monitor its own reception of synchronization signals from the other device. This self-monitoring capability enables accurate failure detection using the existing synchronization infrastructure, without requiring additional monitoring equipment or redundant synchronization lines.
Data Source
AI summary
A method for operating a network with two control devices and at least one peripheral device, wherein each of the control devices, in relation to the peripheral device, is in an active operating state in which it is sending control instructions to the peripheral device or is in an idle operating state in which it is not sending any control instructions to the peripheral device. The control device that is in the active operating state in relation to the peripheral device sends synchronization signals at regular intervals to the other control device and activity signals to the peripheral device. Upon failure of the synchronization signals, the non-active control device checks whether the peripheral device is still receiving activity signals from the active control device. If it is not, the non-active control device assumes control of the peripheral device.