Process Control Switchover Timing for Online Program Updates

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Solution Overview

Problem

Existing process control systems face challenges in updating the online update function without stopping the active apparatus, which is essential for continuous operation and safety in industrial processes.

Innovation Solution

The system includes a first process control apparatus (active) and a second (update) apparatus, where the update apparatus acquires takeover data from the active apparatus to continue system functions and determines the timing for switching, allowing for online system updates without stopping the process control system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the online update function is embedded into the active apparatus in the operating state, then the system can achieve continuous operation during updates, but it is difficult to embed the update function without stopping the apparatus

Engineering Contradiction:

Improvecontinuous operation during updatesVSAvoiddifficulty to embed update function

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The update function is pre-configured in the standby apparatus before switching occurs. The standby apparatus is prepared in advance with the updated program and necessary update functions, so when switching from active to standby, the update capability is already in place without needing to install it during operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The active apparatus and standby apparatus are configured as identical copies with the same hardware and software architecture. This allows the update function to be developed and tested on the standby apparatus independently, then seamlessly transferred to the active apparatus through switching, avoiding the complexity of modifying the running system.

Inventive Principle:

Principle #26Copying

2Reliability

If the active apparatus is stopped to embed the update function, then the update function can be properly installed, but the process control system experiences interruption

Engineering Contradiction:

Improveproper installation of update functionVSAvoidinterruption of process control system

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The standby apparatus is prepared in advance with the updated program and necessary update functions, so when switching from active to standby, the update capability is already in place without needing to install it during operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A standby apparatus is maintained in readiness as a buffer system. This cushioning mechanism ensures that if the active apparatus needs updating, the standby apparatus can immediately take over, preventing any interruption to the process control system while updates are applied.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If the system uses traditional update methods requiring apparatus stoppage, then the update function can be embedded, but the system cannot maintain continuous operation

Engineering Contradiction:

Improvesimplicity of update methodVSAvoidcontinuous operation capability

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The standby apparatus acts as an intermediary during the update process. It receives and validates update programs, prepares them for execution, and seamlessly transitions control from the active apparatus, enabling updates without direct modification of the running system.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12332624B2Process control system, process control apparatus, and program update method

Publication Date: 2025.06.17 YOKOGAWA ELECTRIC CORP

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.