Process Control Program Switchover With Context Transfer Updates
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Solution Overview
Problem
Existing process control systems face challenges in updating programs, such as operating systems, without stopping the system, especially in industrial settings where continuous operation is crucial, and existing methods require complex analysis and processing.
Innovation Solution
A process control system and method that involves pausing non-update target programs, transferring their context, and resuming both non-update and update target programs after updating, allowing for context restoration and initialization without interrupting the system's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the process control system stops to update the program, then the update can be performed completely, but the system operation is interrupted and productivity is reduced
Solution Approach 1:
The system is divided into two independent process control apparatuses (first and second) that can operate separately. The update process segments the system into an active apparatus continuing operation and a standby apparatus receiving updates, allowing program updates without interrupting overall system functionality.
Solution Approach 2:
The standby process control apparatus preloads the updated program before the update is needed. This preliminary action allows the system to switch to the pre-prepared updated program instantly, avoiding interruption of operation while completing the update process.
2Adaptability or versatility
If the system uses a universal device with open specification, then hardware replacement and software updates become possible, but system complexity increases compared to dedicated devices
Solution Approach 1:
The system separates the control functionality into distinct process control apparatuses with clear roles (active and standby). This segmentation manages complexity by creating modular, independently manageable units while maintaining versatility through the ability to update each unit's hardware and software independently.
Solution Approach 2:
The system employs universal process control apparatuses that can perform multiple functions: normal operation, program updates, and context restoration. This multi-functionality reduces the need for specialized dedicated devices while maintaining system manageability through standardized interfaces and procedures.
3Productivity
If the update process requires context transfer and restoration, then program updates can be performed without stopping the system, but the update process becomes more complex
Solution Approach 1:
The system copies the runtime context from the active process control apparatus to the standby apparatus. This copying mechanism enables seamless transition and update without interruption, as the standby apparatus receives a complete snapshot of the operational state that can be restored after update.
Solution Approach 2:
The context data acts as an intermediary that bridges the active and standby apparatuses during the update process. This mediator enables the transfer of operational state information, allowing the system to maintain continuity while performing complex update and restoration operations.
Data Source
AI summary
A first process control apparatus in a process control system executes a non-update target program which is not an update target and an update target program which may be the update target, pauses the non-update target program based on a pause request from an outside, and transfers a context of the non-update target program to a second process control apparatus. The second process control apparatus in the process control system executes the non-update target program which is not the update target and an update target program after update, restores a context of the non-update target program by using the transferred context, initializes a context of the update target program, and causes the second program execution unit to resume the non-update target program and the update target program, based on a resuming request from the outside.