Process Control Switchover for Online Updates Without Shutdown

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing process control systems face challenges in embedding online system update functionality into active apparatuses without requiring them to be stopped, as traditional methods necessitate at least one stoppage for updating, which is not feasible in continuous operation environments like chemical plants.

Innovation Solution

A process control system comprising a first and second apparatus, where the second apparatus includes a data takeover unit to acquire and restore takeover data from the first apparatus, and a timing determiner to determine the switching timing, allowing for online system updates without stopping the system by using a symbol table and address conversion table to manage address changes and cache operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If online system update function is embedded into the active apparatus, then system update capability is improved, but system stoppage is required which reduces productivity

Engineering Contradiction:

Improveonline system update capabilityVSAvoidcontinuous operation

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system is divided into two separate apparatuses: the active apparatus that continues normal operation and the standby apparatus that receives updates. This segmentation allows the update function to be embedded in the standby apparatus without requiring the active apparatus to stop, thus maintaining continuous productivity while enabling online system update capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standby apparatus is prepared in advance with update functionality and receives program updates before they are needed. Context data is transferred and restored in advance, so when switching is required, the transition can occur immediately without stopping the overall system operation.

Inventive Principle:

Principle #10Preliminary action

2Speed

If context data is transferred during operation, then update speed is improved, but data accuracy may deteriorate due to ongoing system changes

Engineering Contradiction:

Improveupdate speedVSAvoidcontext data accuracy

Core Design Contradiction:

SpeedVSMeasurement precision

Solution Approach 1:

The system dynamically determines the optimal timing for context data transfer based on system state. The timing determiner monitors system operations and selects moments when context transfer will have minimal impact on accuracy, balancing update speed with data precision by adapting to real-time system conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses feedback mechanisms to verify context data transfer accuracy. The timing determiner monitors whether the target apparatus has correctly received and restored context data, and can trigger retransmission or correction if accuracy issues are detected, ensuring data integrity while maintaining efficient update speed.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP4068016A1Process control system, process control apparatus, and program update method

Publication Date: 2022.10.05 YOKOGAWA ELECTRIC CORP

Figure 1
Figure 2
Figure 3

AI summary

A process control system includes a first process control apparatus and a second process control apparatus. The second process control apparatus includes a data takeover unit configured to acquire, from the first process control apparatus, takeover data required to be taken over to continue a system function when switching from the first process control apparatus to the second process control apparatus is performed and restore the takeover data in the second process control apparatus and a timing determiner configured to determine a timing when the switching will be performed.