Redundant Control Device Error History Synchronization
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Solution Overview
Problem
Error monitoring in redundant control systems for automation technology is complex due to the need for synchronized error information exchange between remote control devices, which is not efficiently managed, leading to incomplete diagnostic capabilities.
Innovation Solution
A method for error monitoring in a control and data transmission system where redundant control devices exchange error information via a communication network, allowing both local and remote devices to store and display error histories for comprehensive system diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If error information is exchanged between remote control devices via communication network, then diagnostic capability is improved, but system complexity increases
Solution Approach 1:
The control devices perform multiple functions: they control process devices, monitor errors locally, exchange error information via communication network, and display both local and remote error histories. This multi-functionality resolves the contradiction by consolidating diagnostic capabilities across the system rather than requiring separate dedicated monitoring equipment, thereby improving diagnostic capability without proportionally increasing system complexity.
Solution Approach 2:
The communication network acts as an intermediary that enables error information exchange between remote control devices. This mediator allows diagnostic data to be shared across the system without requiring direct physical connection or complex point-to-point wiring, thus improving diagnostic capability while keeping the communication infrastructure relatively simple.
2Adaptability or versatility
If control devices are spatially separated, then system flexibility is improved, but error information exchange becomes more difficult
Solution Approach 1:
The communication network serves as an intermediary that bridges spatially separated control devices, enabling reliable error information exchange despite physical distance. This mediator transmits error data packets between devices, ensuring that spatial separation does not result in information loss and allowing the system to maintain flexibility with distributed components.
Solution Approach 2:
The system implements feedback mechanisms where control devices continuously exchange error information and status updates via the communication network. This feedback loop ensures that even spatially separated devices remain informed about system state, preventing information loss and enabling flexible distributed architecture.
3Difficulty of detecting and measuring
If comprehensive error history is stored on both control devices, then diagnostic capability is improved, but memory requirements increase
Solution Approach 1:
Instead of each control device storing complete error histories independently, the system copies error information from one device to another via the communication network. Each device maintains a local error history and receives copies of remote error data, providing comprehensive diagnostic capability while distributing storage requirements rather than duplicating entire histories on all devices.
Solution Approach 2:
The error history storage is merged across the distributed system through the communication network. Control devices combine their local error data with received remote error data to achieve comprehensive diagnostic capability. This merging approach allows the system to function as a unified diagnostic entity while distributing storage burden across multiple devices.
Data Source
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AI summary
In order to simplify and/or improve error monitoring in a control and data transmission installation 10 for redundant process control, the invention provides a method for error monitoring, in which errors recognised by a first control device 100 are both locally stored and transmitted to at least one redundant, remotely arranged second control device 200 and also stored there, so that the error history of both control devices 100 and 200 is available locally in each case for diagnosis of the overall redundancy system 10. The invention also provides a control and data transmission installation 10 that is designed for carrying out the method and also a control device for use therein.