Shared-Cable Redundancy Protocols for Process Control I/O
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Solution Overview
Problem
The complexity and cost associated with configuring and managing multiple redundancy protocols in process control systems (PCS) for fault-tolerant communications introduce challenges in configuration, asset management, security, and time distribution, particularly due to the need for separate network segments and dedicated physical networks.
Innovation Solution
Implementing multiple network redundancy protocols, such as Fault-Tolerant Ethernet (FTE) and Parallel Redundancy Protocol (PRP), on the same physical cables to provide simultaneous communication capabilities between process controllers and I/O modules, utilizing VLANs to segregate critical and normal communications, and enabling fast fault recovery and high bandwidth needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate physical networks are used for different redundancy protocols, then fault tolerance and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple redundancy protocols (PRP and HSR) onto a single physical network infrastructure. The system allows simultaneous operation of different redundancy protocols over the same physical cables and network segments, eliminating the need for separate dedicated networks for each protocol while maintaining their respective fault tolerance capabilities.
Solution Approach 2:
The network infrastructure is designed to be universal and multi-functional, supporting multiple redundancy protocols concurrently. The same physical network can dynamically adapt to support PRP, HSR, or both protocols simultaneously, making the infrastructure versatile and reducing overall system complexity.
2Reliability
If separate physical networks are used for different redundancy protocols, then protocol isolation and security are improved, but cost and resource utilization worsen
Solution Approach 1:
The patent segments network traffic at the logical layer using virtualization techniques, allowing different redundancy protocols to be isolated and secured while sharing the same physical infrastructure. Traffic from PRP and HSR protocols is segmented into separate virtual channels or VLANs, maintaining protocol isolation without requiring separate physical networks.
Solution Approach 2:
Multiple redundancy protocols share the same physical network resources (cables, switches, ports) while maintaining logical separation. This consolidation reduces the total quantity of network resources required compared to deploying separate dedicated networks for each protocol.
3Device complexity
If multiple redundancy protocols are implemented on the same physical network, then network management complexity is reduced, but protocol interference and conflicts may increase
Solution Approach 1:
The system performs preliminary configuration and registration of multiple redundancy protocols before actual operation. Network devices pre-negotiate protocol coexistence parameters, establish priority schemes, and configure conflict resolution mechanisms in advance, preventing protocol interference during runtime while simplifying ongoing management.
Data Source
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AI summary
A process control system (PCS) includes a cable connection including physical cables including a first cable for connecting between a process controller and an I/O access device, and an independent second cable for connecting the process controller and a second node being the I/O access device or another device. The I/O access device is for coupling to I/O module(s) to receive an output of the I/O access device. An output of the I/O module is coupled to a field device coupled to processing equipment. The process controller and I/O access device each include a processor and memory that implement send and receive logic for communicating using any of multiple redundancy protocols including a first and a second redundant protocol. The cable connection is for supporting simultaneously communicating between the process controller and the second node utilizing both the first redundant protocol and the second redundant protocol.