Redundant Plant Controller Switching for Standby Utilization
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Solution Overview
Problem
The existing redundant controller configuration for process control in plants is not cost-effective due to low utilization of the standby controller, leading to inefficiencies in resource allocation and increased costs.
Innovation Solution
A controller configuration that includes a communication function unit and a redundancy management unit, allowing the controller to switch between active and standby states, thereby optimizing the utilization of redundant controllers and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundant configuration using two controllers is adopted, then system reliability is improved, but cost increases due to low utilization of the standby controller
Solution Approach 1:
The standby controller is designed to perform control calculations not only for its own standby function but also for the active controller. This multi-functionality allows the standby controller to contribute to overall system productivity even during normal operation, reducing waste and improving cost-effectiveness while maintaining reliability
Solution Approach 2:
The standby controller continuously performs control calculations for the active controller during normal operation, ensuring that its computational resources are continuously utilized. This eliminates idle time and ensures that when switching occurs, the standby controller is already prepared and synchronized, maintaining continuous useful action without interruption to system reliability
2Productivity
If the standby controller continuously performs control calculations, then productivity is improved, but device complexity increases
Solution Approach 1:
The controller dynamically changes its function based on operational state. During normal operation, the standby controller performs calculations for the active controller; upon detecting a switch to standby state, it automatically transitions to performing calculations for itself. This dynamic adaptation allows high productivity without permanent structural complexity
Solution Approach 2:
The controller is designed to serve itself by automatically detecting its operational state and adjusting its calculation target accordingly. When in standby state, it automatically switches to performing control calculations for itself without external intervention, simplifying the overall system architecture while maintaining high utilization
Data Source
AI summary
A controller is a controller forming, with another controller, a redundant controller. The controller includes a communication function unit that performs communication with an external device capable of executing control calculation needed for process control for a plant, and a redundancy management unit that switches states of the controller between an active state where a result of the control calculation obtained from the external device via the communication function unit is reflected in the process control and a standby state where the result of the control calculation is not reflected in the process control. The redundancy management unit switches the states of the controller to bring one of the controller and the another controller into the active state.