Software Update Method for Control Devices Using Redundant Computing
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Solution Overview
Problem
Current safety-critical automation tasks in industrial settings require continuous monitoring and control, but existing methods cannot reliably update software versions on standard industry hardware without disrupting machine control, necessitating specialized and costly fail-safe PLCs.
Innovation Solution
A procedure for updating software versions on a circuit arrangement using redundant electronic computing devices with external data sensors, allowing for seamless upgrades and emergency control functions on standard industry hardware, ensuring continuous machine operation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated fail-safe PLC hardware is used for safety-critical control functions, then system reliability is improved, but hardware cost and complexity increase
Solution Approach 1:
The patent creates a virtual copy of the fail-safe PLC control function by implementing it as software on standard hardware. The control function is replicated across multiple electronic computing devices, with at least one being a fail-safe device, allowing the safety-critical functionality to be distributed and virtualized rather than requiring dedicated specialized hardware for each instance.
Solution Approach 2:
The patent replaces the mechanical/electrical dedicated PLC hardware system with a software-based control system running on standard electronic computing devices. By substituting specialized hardware with software implementations on general-purpose computers, the system achieves the same safety-critical functionality without requiring dedicated fail-safe PLC hardware, thereby reducing hardware complexity and cost.
2Adaptability or versatility
If software updates are performed on control devices, then software adaptability is improved, but control continuity deteriorates
Solution Approach 1:
The patent performs preliminary actions by preparing and validating the new software version on a second electronic computing device before actually switching it to control the machine. The software update is tested and verified in advance on the redundant device, ensuring that when the switch occurs, control continuity is maintained without interruption or loss of safety monitoring.
Solution Approach 2:
The patent introduces a second electronic computing device as an intermediary during the software update process. This intermediary device serves as a buffer that can take over control functions while the primary device undergoes software updates, thereby mediating between the need for software adaptation and the requirement for continuous uninterrupted control.
3Ease of manufacture
If standard industrial hardware is used instead of dedicated fail-safe PLCs, then cost is reduced, but proving safety-critical functionality becomes more difficult
Solution Approach 1:
The patent implements comprehensive feedback mechanisms where the control function continuously monitors its own operation and the state of the machine. The system includes self-diagnosis capabilities that provide feedback on the operational status, safety conditions, and software integrity, making it easier to verify and maintain safety-critical functionality on standard hardware through continuous monitoring and status reporting.
Data Source
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AI summary
The invention relates to a method for updating a software version for a control function (24) for a circuit arrangement (16) for controlling a machine (12), comprising the steps of: receiving a data packet to update the software version; storing the data packet in a first storage device (56) and storing the data packet in a second storage device (58); extending the first electronic computing device (18) with a further external data sensor (60) and extending the second electronic computing device (28) with yet another external data sensor (62); releasing the software version for updating by means of the further external data sensor (60) and the yet another data sensor (62); updating the software version on the second electronic computing device (28); and updating the software version on the first electronic computing device (18).Furthermore, the invention relates to a computer program product, a computer-readable storage medium and a circuit arrangement (16).