Distributed Process Control Redundancy With Synchronized Configuration Nodes
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Solution Overview
Problem
Current network-distributed process control systems face challenges in maintaining continuous operation and efficient redundancy management, particularly in detecting node failures and reconfiguring roles without skilled personnel, leading to potential system downtime and security vulnerabilities.
Innovation Solution
A system utilizing general-purpose nodes configured to perform specific network roles, with redundant counterparts for uninterrupted operation, allowing any node to be replaced without expert intervention, and implementing synchronization between configuration nodes for identical operation and enhanced security through synchronized configuration management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant devices are applied with identical virtual addresses, then system availability is improved during node failure, but device complexity increases and task-specific redundancy problems are limited
Solution Approach 1:
The patent applies universality by using a single Layer 3 virtual address space for both node identification and redundancy management functions. The redundant devices share the same virtual address and can perform any network role (data acquisition, processing, archiving, configuration), eliminating the need for separate redundancy management layers and enabling flexible role assignment while maintaining system availability.
2Adaptability or versatility
If IP multicast is used for virtual address space, then communication flexibility is improved, but reliability deteriorates due to lack of TCP connection guarantees
Solution Approach 1:
The patent introduces an intermediary mechanism at Layer 3 (network layer) that provides reliable packet delivery confirmation for multicast communications. This intermediary layer ensures that configuration messages and heartbeat signals are reliably delivered to redundant nodes, combining the flexibility of multicast with the reliability of confirmed delivery, avoiding the need for additional Layer 4 checks.
3Difficulty of detecting and measuring
If separate communication channels are maintained for redundant nodes, then fault detection capability is improved, but network stability deteriorates due to channel isolation
Solution Approach 1:
The patent merges the communication channels by allowing redundant nodes to participate in the same Layer 3 network using identical virtual addresses. Heartbeat messages and configuration updates are transmitted through the unified network infrastructure, enabling continuous fault detection while maintaining network stability. The redundant nodes remain integrated in the same communication domain rather than being isolated on separate channels.
4Object-affected harmful factors
If skilled personnel are required for node replacement, then system security is improved, but ease of repair deteriorates
Solution Approach 1:
The patent implements self-service by designing the system with automatic role assignment and configuration inheritance mechanisms. When a redundant node is activated, it automatically receives the appropriate node configuration and assumes the required network role without manual intervention. This self-configuration capability allows unskilled personnel to perform node replacements while maintaining system security through automated authentication and role management.
Data Source
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AI summary
The invention is a network-distributed process control system comprising operative nodes (10) constituting a network adapted to operate determined by a network configuration, each operative node (10) having a node configuration determining its network role (12), the node configurations altogether constituting the network configuration. The network-distributed process control system is characterised in that the operative nodes (10) are created by configuring general-purpose nodes (14), wherein - each general-purpose node (14) is configured for a respective network role (12) required for operating as the given operative node (10), and - at least two of the operative nodes (10) are configuration nodes (16) that are adapted for storing network configuration and for assigning the node configurations of the operative nodes (10) connected to them over the network, and are synchronized with each other for identical operation, the system further comprising - a platform software on the general-purpose nodes (14) prepared to perform any of the network roles (12), the software being adapted for automatically receiving, from a configuration node (16), the node configuration to be assigned, and for operating as an operative node (10) based on the received node configuration. The invention is furthermore a method for managing redundancy of configuration nodes (16) in the process control system.