Shared Interface Redundancy for PCS I/O Network Segregation
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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 between process controllers and I/O modules introduce challenges in areas like configuration, security, and asset management, especially when different data flows require varying levels of bandwidth and fault recovery rates.
Innovation Solution
Implementing two separate physical cables that utilize both Fault-Tolerant Ethernet (FTE) and Parallel Redundancy Protocol (PRP) redundancy protocols simultaneously, allowing for flexible fault recovery and data segregation across virtual local area networks (VLANs) to meet diverse communication needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate physical networks are used for different data flows with different redundancy protocols, then fault tolerance and reliability are improved, but device complexity and configuration complexity increase
Solution Approach 1:
The patent merges multiple redundancy protocols (FTE and PRP) onto a single physical network infrastructure. The system allows simultaneous operation of both FTE and PRP protocols over the same physical cables between process controllers and I/O modules, eliminating the need for separate physical networks while maintaining the reliability benefits of both protocols.
Solution Approach 2:
The physical network infrastructure is designed to support multiple functions and protocols simultaneously. The same physical cables and network interfaces can carry both FTE and PRP protocol traffic, making the network universal and multi-functional rather than requiring dedicated separate networks for each protocol type.
2Reliability
If multiple redundancy protocols are implemented on separate physical networks, then fault recovery capability is improved, but cost increases
Solution Approach 1:
The patent combines multiple redundancy protocols onto shared physical infrastructure, reducing the total amount of cabling and network hardware required. By allowing FTE and PRP to coexist on the same physical network, the system avoids duplicating physical resources, thereby reducing implementation costs while maintaining robust fault recovery capabilities.
3Adaptability or versatility
If separate physical networks are deployed for different communication needs, then adaptability to different bandwidth and fault recovery requirements is improved, but ease of operation deteriorates
Solution Approach 1:
The patent segments different data flows and communication requirements into virtual networks or VLANs that can be logically separated while physically sharing the same infrastructure. This allows different bandwidth and fault recovery requirements to be accommodated through logical segmentation rather than physical separation, simplifying network management.
Solution Approach 2:
The network infrastructure is designed to be universal, supporting multiple protocol types and communication requirements over the same physical medium. This multi-functionality reduces the operational burden of managing multiple separate networks while maintaining the adaptability needed for different communication needs.
Data Source
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.