Redundant PC System Using Virtualization for Real-Time Control
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Solution Overview
Problem
Existing process control systems face challenges in maintaining real-time operability and high reliability due to limitations in TCP/IP communication, increased costs and failure rates from dedicated interface cards, and the need to continuously update software and hardware over a lengthy plant life cycle, which disrupts system functionality and increases costs.
Innovation Solution
A redundant PC system with a host OS featuring a virtualization unit, a redundant unit, and a real-time communication unit operates as separate processes, using universal NICs and a PC redundancy management tool to manage switching and maintenance, allowing for real-time communication and redundancy without relying on guest OS or application software, thus reducing costs and maintaining functionality across hardware and software generations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If dedicated interface cards for Vnet/IP are mounted on each PC to perform real-time communication, then real-time operability is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by enabling standard Ethernet interface cards to perform multiple functions - both general TCP/IP communication and real-time Vnet/IP communication - through a gateway PC running Vnet/IP software. This eliminates the need for dedicated real-time interface cards on each PC, reducing device complexity while maintaining real-time operability through the centralized gateway architecture.
2Reliability
If redundant PCs with dedicated interface cards are implemented to improve reliability, then system reliability is improved, but cost and device complexity increase
Solution Approach 1:
The gateway PC running Vnet/IP enables standard interface cards to provide real-time communication capabilities, allowing redundant PC configurations to achieve high reliability without requiring expensive dedicated real-time interface cards on each redundant unit. The gateway consolidates the real-time processing function across multiple PCs.
Solution Approach 2:
The gateway PC acts as an intermediary that mediates between standard TCP/IP communication and real-time Vnet/IP communication. It translates and routes real-time communication requests through standard interface cards, enabling redundant PC systems to achieve high reliability with reduced complexity by eliminating dedicated interface cards from individual PCs.
3Ease of operation
If TCP/IP communication is used for Ethernet networks, then ease of operation and adaptability are improved, but real-time operability deteriorates
Solution Approach 1:
The gateway PC serves as an intermediary that translates between standard TCP/IP protocols and real-time Vnet/IP protocols. It receives standard TCP/IP packets, processes them through the Vnet/IP real-time communication stack, and transmits real-time traffic with guaranteed timing, thereby maintaining ease of operation with standard protocols while achieving real-time performance.
Solution Approach 2:
The system segments communication functions by separating standard TCP/IP communication handling from real-time Vnet/IP communication handling. The gateway PC dedicates specific resources and processing paths for real-time traffic, isolating it from general-purpose TCP/IP traffic to ensure real-time operability while maintaining compatibility with standard protocols.
4Adaptability or versatility
If hardware and software are updated continuously over a 30-year plant life cycle, then adaptability is improved, but system stability and reliability deteriorate
Solution Approach 1:
The gateway PC running Vnet/IP provides a stable real-time communication foundation that remains consistent across hardware and software updates. Standard PCs and interface cards can be updated periodically while the gateway maintains the real-time communication protocol and timing, allowing the system to adapt to new hardware generations without compromising the stability of real-time operations.
Data Source
AI summary
A redundant PC system includes a plurality of redundant PCs which is to be connected through a network. Each of the redundant PCs includes hardware on which an interface for connection to the network is mounted and a host OS configured to operate on the hardware. The host OS is provided with a virtualization unit, and a redundant unit and a real-time communication unit, the redundant unit and the real-time communication unit being configured to operate as separate processes independent of the virtualization unit. The redundant unit is configured to perform a control monitoring for making a PC redundant via a universal interface.