Plant Configuration Sync Across Partitioned Networks
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Solution Overview
Problem
In industrial plants with distributed control systems, synchronizing configuration data across multiple servers is challenging due to network interruptions and inconsistencies, which can lead to misconfiguration and operational issues.
Innovation Solution
A method involving partitioning the network into sub-networks, storing configuration data on local servers, updating data during network interruptions, and re-establishing consistency by overwriting unchanged or older data on remote servers using a 'checking unchanged' strategy, with a central server managing data synchronization and a journal for change tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If configuration data is distributed across multiple servers in sub-networks, then system availability and local autonomy are improved, but data consistency and synchronization reliability deteriorate during network interruptions
Solution Approach 1:
The system performs preliminary actions by storing configuration data locally on each server before network interruptions occur. This allows each server to continue operating with its local copy of the configuration data even when the network connection is interrupted, maintaining local autonomy while preserving data consistency through pre-synchronization.
Solution Approach 2:
The system implements a feedback mechanism where servers continuously monitor network connection status and automatically initiate synchronization operations when the connection is restored. This feedback loop ensures that any changes made during network interruptions are detected and resolved, maintaining data consistency across distributed servers.
2Productivity
If configuration data is updated locally during network interruptions, then operational continuity is improved, but risk of data inconsistency and misconfiguration increases
Solution Approach 1:
Before allowing local updates during network interruptions, the system performs preliminary checks to identify which configuration data needs to be synchronized. This preliminary action ensures that only necessary updates are made locally, reducing the risk of inconsistency while maintaining operational continuity.
Solution Approach 2:
The system introduces an intermediary synchronization mechanism that mediates between local updates and remote data. When the network connection is restored, the intermediary process compares local changes with remote data, resolves conflicts, and ensures consistency, allowing local updates without compromising configuration accuracy.
3Reliability
If all configuration data is synchronized across all servers continuously, then data consistency is improved, but network bandwidth consumption and system complexity increase
Solution Approach 1:
The system segments the configuration data into different categories and prioritizes synchronization for critical data. Instead of continuously synchronizing all data, only essential configuration changes are propagated across servers, reducing network bandwidth consumption and simplifying the synchronization system while maintaining data consistency for important parameters.
Solution Approach 2:
The system implements periodic synchronization instead of continuous synchronization. Configuration data is synchronized at specific intervals or triggered by significant events, reducing network bandwidth consumption and system complexity while maintaining adequate data consistency across distributed servers.
4Stability of the object's composition
If network connection is interrupted to isolate failures, then system stability is improved, but ability to synchronize and detect configuration changes deteriorates
Solution Approach 1:
The system implements feedback mechanisms that allow servers to detect configuration changes even during network interruptions. Each server monitors its local configuration changes and maintains a record of modifications. When the network connection is restored, the feedback mechanism enables automatic detection and synchronization of these changes, preventing information loss while maintaining system stability during interruptions.
Data Source
AI summary
A system and method includes partitioning a network into first and second sub-networks connected by a network connection. A first component with first configuration data and a first local server are located in the first sub-network; a second component with second configuration data and a second local server are located in the second sub-network. The first configuration data is stored on the first and second local servers. The network connection is interrupted and the first configuration data is updated on the first local server. The network connection is re-connected, and if the first configuration data on the second local server is unchanged, the first configuration data on the second local server is overwritten.