Redundant PLC Runtime Data Sync Without Blocking Write Access
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Solution Overview
Problem
Existing redundant automation systems face challenges in seamlessly synchronizing and transferring dynamic runtime data during coupling and updating phases, leading to potential data loss and increased costs due to blocked write access during synchronization processes.
Innovation Solution
Implementing independent program units for data synchronization that allow for continuous data recording and synchronization, enabling write access during the synchronization phase by creating a target file for dynamic runtime data and ensuring the sequence of write accesses is identical on both subsystems, thus preventing data loss and simplifying the implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If write access to persistent data is blocked during the syncup process to ensure data consistency, then data consistency between subsystems is improved, but productivity is worsened due to halted data acquisition and continuous modification
Solution Approach 1:
The patent segments the data file into two separate files: a source file accessible to the control program for continuous writing, and a target file used for synchronization with the second subsystem. This segmentation allows write operations to continue uninterrupted while maintaining data consistency during the syncup process.
Solution Approach 2:
The source file acts as an intermediary between the control program and the target file. The control program writes to the source file continuously, while synchronization data is copied from the source file to the target file, allowing both continuous writing and consistent synchronization without blocking operations.
2Reliability
If all status information is copied to the newly added PLC during the syncup process, then reliability of the redundant system is improved, but loss of information is worsened due to potential loss of dynamic runtime data during the copying process
Solution Approach 1:
The system performs preliminary actions by continuously maintaining a current copy of status information in the source file before synchronization is needed. This ensures that when synchronization occurs, the most up-to-date data is already available, preventing any loss of dynamic runtime data.
Solution Approach 2:
The control program continues to write to the source file continuously throughout the syncup process without interruption. This continuity of useful action ensures that dynamic runtime data is never lost, as the writing process proceeds uninterrupted while synchronization data is copied to the target file.
3Manufacturing precision
If the control program is synchronized with the independent program unit during the update phase, then manufacturing precision of the synchronization process is improved, but device complexity is worsened due to multiple synchronized program units
Solution Approach 1:
The patent extracts the synchronization functionality into a separate, independent program unit that operates independently from the main control program. This extraction allows the control program to focus on its primary control functions while the independent program unit handles synchronization, reducing the complexity burden on the main control logic.
Data Source
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AI summary
The invention relates to a redundant automation system (100) comprising a first subsystem (1) and a second subsystem (2), each of which has a control program (P1, P2) for controlling a technical process and is identically configured. A synchronization connection (3) is provided between the first subsystem (1) and the second subsystem (2). In the first subsystem (1), state information (Z1) is stored in a source file (QD), which includes static configuration data (K1) and dynamic runtime data (L1). To enable seamless updating of the second subsystem (2), a first data comparison device (11) is configured with a first independent program unit (T1), which in turn is configured to read the dynamic runtime data (L1) of the first subsystem from the source file (QD) step by step to update the dynamic runtime data (L2) of the second subsystem (2).and to synchronize the data contents of these renewed write accesses to the second subsystem (1), and a second data comparison device (12) is designed, with a second independent program unit (T2), which in turn is designed to gradually receive the renewed write accesses and subsequently save them to a target file (ZD).