Redundant Automation Controllers With Configurable Cross-Loading
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Solution Overview
Problem
High availability industrial control systems require dedicated high-speed data links for bumpless transfer of control, leading to increased costs and complexity, which is not necessary for applications that do not demand full synchronization and high-speed performance.
Innovation Solution
An industrial control system that eliminates the need for a dedicated high-speed data link, allowing users to configure levels of program and data synchronization, enabling trade-offs between features and performance, and utilizing network communication for cross-loading information between primary and secondary controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated high-speed data link is used for bumpless transfer of control between primary and secondary controllers, then control continuity and reliability are improved, but system cost and complexity increase
Solution Approach 1:
The patent extracts the dedicated high-speed data link from the system, eliminating this separate communication path. Instead, the system uses the existing Ethernet network infrastructure for all communication between primary and secondary controllers, thereby reducing hardware complexity while maintaining control continuity through software-based synchronization protocols
Solution Approach 2:
The existing Ethernet network interface is made multi-functional, serving both standard network communication and the previously dedicated high-speed synchronization function. This universal interface handles control data, I/O data, and synchronization information through a single communication channel, eliminating the need for separate dedicated links
2Reliability
If full synchronization of program and data is implemented between primary and secondary controllers, then control reliability is improved, but data transfer requirements and processing power increase
Solution Approach 1:
The system implements partial synchronization by selectively transferring only critical data elements between controllers. Instead of full program and data synchronization, the patent identifies and transfers only the essential I/O data and control state information needed for seamless failover, reducing processing requirements while maintaining adequate reliability
Solution Approach 2:
Different levels of synchronization are applied to different data types based on their criticality. The system applies full synchronization to critical control data while using lighter synchronization mechanisms for less critical information, optimizing processing power usage by matching synchronization intensity to data importance
3Reliability
If a dedicated high-speed data link and full synchronization system are deployed, then bumpless transfer capability is improved, but component cost and board real-estate increase
Solution Approach 1:
The patent merges the dedicated high-speed data link function with the existing Ethernet network interface. By combining these functions into a single interface, the system eliminates redundant hardware components such as separate communication processors, transceivers, and physical connection infrastructure, thereby reducing component costs and board real-estate while maintaining bumpless transfer capability through software optimization
Data Source
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AI summary
A high availability industrial automation system in disclosed. The system has a primary industrial automation controller, a secondary industrial automation controller, and a communication network connected to the primary industrial automation controller and the secondary industrial automation controller. The primary industrial automation controller includes a processor and a memory configured to store a plurality of instructions, a plurality of automation tasks, input/output (I/O) data, and internal storage data. The processor is operative to execute the plurality of instructions to cross load information from the primary industrial automation controller to the secondary industrial automation controller. The cross loading of information can be less than the maximum amount of communicable information capable of being cross loaded. Also disclosed are methods of communicating over the high availability industrial automation system.