Redundant Automation Control with Delayed Output Takeover
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Solution Overview
Problem
Automation systems in manufacturing and process automation require high fault tolerance to ensure continuous operation despite errors such as telegram failures or subscriber interruptions in the transmission path, which existing systems struggle to address effectively.
Innovation Solution
Implementing a method with control redundancy using two controllers, where one controller cyclically generates output data with a time delay, allowing the second controller to seamlessly take over in case of a malfunction by utilizing pre-stored output data from the first controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single controller is used to control the automation process, then the device complexity is reduced, but the reliability decreases due to potential malfunctions without backup
Solution Approach 1:
The second controller is pre-configured with the automation program and stores output data from previous control cycles before a malfunction occurs. This preliminary preparation enables the second controller to immediately take over control of the automation process without delay when the first controller malfunctions, thus improving reliability while maintaining acceptable device complexity.
2Reliability
If the second controller immediately takes over upon malfunction detection, then the reliability is improved, but the loss of time occurs due to switching and synchronization requirements
Solution Approach 1:
The second controller continuously receives and stores output data from the first controller in advance before a malfunction occurs. This preliminary action ensures that when switching is required, the second controller already has the necessary output data ready, eliminating delays associated with real-time data generation and synchronization during the takeover process.
3Productivity
If output data is transmitted in real-time from first controller to second controller, then the productivity is maintained, but the loss of time occurs due to transmission delays and processing overhead
Solution Approach 1:
The second controller receives and stores output data from the first controller in advance during normal operation, before any malfunction occurs. This preliminary data accumulation eliminates the need for real-time data transmission and processing during critical takeover scenarios, thereby reducing transmission delays and processing overhead while maintaining productivity.
Data Source
AI summary
A method for controlling an automation system having control redundancy is provided. The automation system has at least a first controller, a second controller and a plurality of field devices connected to the first and second controller via a data bus, with the first and second controller configured to cyclically control an automation process of the automation system. The method comprises cyclically controlling the automation process via the first controller, determining a malfunction of the first controller during an (n+x)-th control cycle, where the (n+x)-th control cycle is carried out x control cycles later in time than the n-th control cycle, and sending out an n-th set of output data via a second input-output unit of the second controller to the plurality of field devices in the (n+x)-th control cycle, for controlling the automation process. An automation system is configured to carry out the method.