Safe Automation Link Reparameterization Without Plant Interruption
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Solution Overview
Problem
Existing methods for changing communication parameters in functionally safe communication links between automation devices in industrial plants often result in system interruptions, disrupting continuous operation and production.
Innovation Solution
A method where the first automation device sends a request for parameter change to the second, freezing process images and changing communication parameters without interrupting communication, using timers for watchdog functions and signature verification to ensure seamless reparameterization and restart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If communication parameters are changed in a functionally safe communication link between automation devices, then the configuration can be updated to adapt to new requirements, but the system operation is interrupted and production continuity is disrupted
Solution Approach 1:
The patent applies preliminary action by having the first automation device send a parameter change request to the second automation device before actually changing its own parameters. The second device prepares and confirms readiness for the parameter change in advance, ensuring that both devices are synchronized and ready for the transition, thus avoiding communication interruptions and maintaining production continuity.
2Productivity
If communication parameters are changed during operation, then uninterrupted plant operation can be maintained, but the complexity of coordinating parameter changes between multiple automation devices increases
Solution Approach 1:
The patent implements feedback through an acknowledgment mechanism where the second automation device responds to parameter change requests with a readiness acknowledgment. This feedback loop ensures that the first device receives confirmation before executing the parameter change, coordinating the transition smoothly between devices while maintaining uninterrupted operation and managing complexity through structured communication.
3Reliability
If the process image is frozen immediately when parameter change is requested, then communication can be restarted quickly with updated parameters, but the time for completing the parameter change operation increases
Solution Approach 1:
The patent applies preliminary action by freezing the process image in the second automation device immediately when the parameter change request is received, before the actual parameter change is executed. This ensures that the process data remains consistent and reliable during the transition, while the first device can proceed with its parameter change without waiting for the second device to complete its update, thus minimizing reparameterization time.
Data Source
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AI summary
To enable a configuration change during operation without disruption, a first automation device (A) sends a parameter change request (31) to a second automation device (B), and the second automation device (B) responds to the request by sending a readiness acknowledgment (32) to the request (31), and immediately upon sending the readiness acknowledgment (32), an output process image is frozen in the second automation device (B), and the communication parameters (KP2) for the second automation device (B) are changed, and furthermore, the first automation device (A) responds by immediately stopping communication upon receiving the readiness acknowledgment (32) in the first automation device (A) and changing the communication parameters (KP2) for the first automation device (A), thereby freezing an input process image.