Process Control Function Updates With Parallel State Comparison
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Solution Overview
Problem
The existing methods for updating process control functions in network-centric process control systems are inefficient and do not adequately ensure that the new version operates identically to the original version, and there is a need for seamless integration and rollback capabilities.
Innovation Solution
A method and system that involves testing a new version of the process control function in parallel with the existing version, comparing states at various points in the cycle, and switching over to the new version only after satisfactory performance is confirmed, utilizing a testing and switchover control module to manage this process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a new version of the process control function is introduced to improve the system, then the productivity and continued improvement are enhanced, but the reliability and stability may be compromised if the new version contains faults or deviations
Solution Approach 1:
The patent implements preliminary testing of the new version by executing it in parallel with the old version and comparing their outputs before full deployment. This preliminary action allows verification of the new version's correctness without immediately exposing the system to potential faults, thus resolving the contradiction between improvement and reliability.
Solution Approach 2:
The patent establishes a safety mechanism where the old version remains as a backup during the transition period. If the new version proves defective during testing, the system can revert to the old version, providing a cushion against reliability risks while still allowing productivity improvement through version updates.
2Measurement precision
If parallel testing of new and old versions is implemented to ensure reliability, then the measurement precision and verification are improved, but the device complexity and operational overhead increase
Solution Approach 1:
The patent introduces a testing and switchover control module as an intermediary that manages the parallel execution and comparison of old and new versions. This mediator handles the complexity of coordination, data collection, and comparison logic, allowing the core process control functions to remain simple while achieving precise verification.
Solution Approach 2:
The patent combines multiple functions (testing, comparison, and switchover control) into a single integrated control module. This merging reduces overall system complexity by consolidating the testing infrastructure rather than requiring separate systems for each function, thus resolving the contradiction between measurement precision and device complexity.
3Manufacturing precision
If comprehensive state comparison is performed to verify version equivalence, then the manufacturing precision and quality control are improved, but the loss of time and computational resources increase
Solution Approach 1:
The patent performs comparison of critical states (input states, output states, and intermediate states) rather than exhaustive analysis of every possible parameter. This partial action approach achieves sufficient validation precision for process control applications without incurring excessive time costs, resolving the contradiction between manufacturing precision and time loss.
4Reliability
If redundancy with identical process control functions is maintained for fault tolerance, then the reliability is improved, but the adaptability and ability to introduce updates are reduced
Solution Approach 1:
The patent transforms the static redundancy model into a dynamic one where the system can transition between old and new versions based on testing results. The redundancy mechanism becomes adaptive, allowing the system to maintain reliability through version A while enabling updates to version B, thus resolving the contradiction between reliability and adaptability.
Data Source
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AI summary
A method for managing introduction of updates in a process control function in a network centric process control system (10), where a first version of the process control function is being run in a controller node (12) and has a number of original states and a second version of the process control function is provided in the process control system (10), a first part of which is provided in a process control function handling node (14), the second version having a number of new states corresponding to the original states. The method comprises testing the second version, comprising comparing new states of the second version with corresponding original states of the first version and switching over to using the second version, after finding has been made based on the comparison of the states of the first and second versions of the process control function, that the second version is satisfactory.