Process Controller Migration via Dual-Network Interfaces
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Solution Overview
Problem
Industrial process control and automation systems face challenges in upgrading devices while maintaining operational continuity, especially when upgrading to devices with different software bases, physical form-factors, cabinet layouts, power subsystems, or supervisory network mediums, leading to disruptions and difficulties in maintaining control and data integrity.
Innovation Solution
The method involves installing new communication interfaces in process controllers to enable communication over different supervisory networks, allowing for on-process migration of controllers and servers while ensuring control and data integrity is maintained, using techniques like database image synchronization and dynamic state data transfers to facilitate the upgrade of unlike devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new communication interfaces are installed and device migration is performed, then adaptability and network compatibility are improved, but device complexity and migration difficulty increase
Solution Approach 1:
A dual-network interface system acts as an intermediary during migration. The old supervisory network interface and new supervisory network interface coexist temporarily, allowing gradual transition. Data can be routed through either interface, enabling seamless migration without forcing immediate complete system replacement.
Solution Approach 2:
The new communication interface is installed and configured in advance before actual migration occurs. The new interface is prepared and tested while the system continues to operate on the old network, allowing migration to proceed without disruption when the switch is made.
2Adaptability or versatility
If on-process migration is performed between different device types, then system upgrades and feature improvements are achieved, but control stability and operational reliability may be compromised
Solution Approach 1:
The migration process is designed to maintain continuous process control throughout the upgrade. The system transitions from old device to new device without interrupting the controlled process, ensuring continuous monitoring and control functions remain active during the entire migration sequence.
Solution Approach 2:
Redundant control paths and backup communication channels are established before migration begins. This cushioning ensures that if issues arise during migration, the system can fall back to previous configurations, protecting against loss of control stability.
3Speed
If communication interfaces are updated to different network types, then network modernization and data transmission capability are improved, but system integration complexity and configuration difficulty increase
Solution Approach 1:
The process controller is designed with multi-functional communication capabilities, able to operate on both old and new supervisory networks. This universal interface design allows the same hardware platform to support multiple network protocols and types, reducing integration complexity despite network modernization.
Data Source
AI summary
A method includes installing new communication interfaces in first process controllers of an industrial process control and automation system. The first process controllers are configured to communicate over a first supervisory network, and the communication interfaces are configured to communicate over a second supervisory network of a different type. The method also includes migrating the first process controllers to second process controllers of a different type while maintaining control over an industrial process being controlled by the first process controllers. The second process controllers are configured to communicate over the second supervisory network.