Redundant Ethernet Backplane for Fault-Tolerant Modular I/O
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing distributed modular I/O systems in industrial automation lack true fault tolerance due to single-point failures in their backplane data paths, which can disrupt operations in critical applications requiring continuous process control.
Innovation Solution
The implementation of a redundant dual Ethernet backplane network with independent and parallel communication paths between network adapters and I/O devices, utilizing redundant network and I/O module switches to ensure continuous operation even if one path fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single backplane network is used to connect network adapters and I/O devices, then the system structure is simple and cost-effective, but the system lacks fault tolerance and operations are disrupted when the backplane fails
Solution Approach 1:
The backplane network is segmented into two independent parallel networks (first backplane network and second backplane network), each capable of carrying data traffic separately. This segmentation allows the system to isolate failures to one network while the other continues to operate, thereby improving fault tolerance without requiring a complete system redesign
Solution Approach 2:
The system implements redundant backplane networks and redundant network switches beforehand as a preventive measure. When a failure occurs in one backplane network or switch, the system has pre-configured backup paths through the second backplane network and redundant switches, cushioning against the failure and maintaining continuous operation
2Reliability
If redundant network switches are implemented in the backplane network, then fault tolerance is improved, but the device complexity and cost increase
Solution Approach 1:
The network switching function is segmented across multiple switches distributed throughout the backplane network rather than using a single centralized switch. This segmentation provides redundancy at each segment, allowing local failures to be isolated without affecting the entire system
Solution Approach 2:
Redundant network switches are implemented as copies of the original switch, providing identical functionality and capabilities. When one switch fails, its copy takes over the network traffic, ensuring continuous operation without requiring complex failover logic or different types of backup devices
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A modular I/O system for an industrial automation network includes a network adapter including first and second adapter modules, wherein each adapter module is configured for connection with an industrial network. The I/O system further includes a first I/O device with first and second I/O modules each configured for operative connection to a controlled system for input/output of data with respect to the controlled system. The I/O system further includes first and second independent backplane data networks that connect each of the first and second adapter modules to each of the first and second I/O modules. The network adapter includes first and second removable backplane network switches and the first I/O device includes third and fourth removable backplane network switches that establish the backplane networks. The backplane network switches can be Ethernet gigabit switches.