Distributed Process Control Computing for Shared Failover Backup

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional process control systems require one-to-one redundancy between primary and backup components, leading to increased costs, complexity, and rigidity, as well as laborious reconfiguration when adapting to changing demands.

Innovation Solution

A distributed computing environment is implemented, allowing compute nodes with varying hardware and operating systems to collaborate and back up applications, using allocation algorithms to distribute data and applications, and providing a communication channel for seamless failover and load balancing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If one-to-one redundancy between primary and backup components is implemented, then system reliability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple backup components share a single common backup resource instead of each primary component having its own dedicated backup. The system consolidates redundancy resources, allowing one backup component to serve multiple primary components, thereby reducing overall system complexity while maintaining reliability through shared backup capacity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The backup component is designed to universally support multiple primary components rather than being dedicated to a single primary component. This multi-functional backup can assume the role of any failed primary component, reducing the total number of backup components needed while ensuring system reliability through flexible resource allocation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If one-to-one redundancy between primary and backup components is implemented, then system reliability is improved, but cost increases

Engineering Contradiction:

Improvesystem reliabilityVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The system merges multiple backup resources into a shared pool, eliminating the need for separate backup components for each primary component. This consolidation reduces the total quantity of hardware required, lowering system cost while maintaining reliability through the shared backup capacity that can serve any failed primary component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A single backup component is designed to universally replace any of the primary components, making it a multi-functional resource. This approach reduces the total number of components needed compared to dedicated one-to-one backups, thereby reducing material costs and system expenditure while ensuring reliability through flexible failover capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If additional primary and backup components are added to increase system resources, then available process control system resources are improved, but device complexity and cost increase

Engineering Contradiction:

Improveavailable process control system resourcesVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system employs universal backup components that can serve multiple primary components, allowing the system to scale resources efficiently. When additional resources are needed, the system adds components that can be shared across multiple functions, increasing available process control resources without proportionally increasing system complexity through dedicated one-to-one mappings.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If configuration of control system components is altered in conventional implementations, then system adaptability is improved, but reconfiguration time and labor increase

Engineering Contradiction:

Improvesystem adaptabilityVSAvoidreconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system replaces physical rewiring and mechanical reconfiguration with software-based configuration management. Control system component configurations are managed through programmable interfaces and software settings rather than physical wire connections, allowing rapid reconfiguration by changing software parameters without time-consuming physical rewiring operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10908574B2Distributed computing in a process control environment

Publication Date: 2021.02.02 SCHNEIDER ELECTRIC SYSTEMS USA INC

AI summary

High availability and data migration in a distributed process control computing environment. Allocation algorithms distribute data and applications among available compute nodes, such as controllers in a process control system. In the process control system, an input/output device, such as a fieldbus module, can be used by any controller. Databases store critical execution information for immediate takeover by a backup compute element. The compute nodes are configured to execute algorithms for mitigating dead time in the distributed computing environment.