Storage Appliance Backup for Automatic Controller Platform Recovery
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Solution Overview
Problem
In network control systems, the backup controller fails to take over when the primary controller fails unless fully synchronized, requiring user intervention for restoration, especially when hardware has failed and the application module needs to be replaced.
Innovation Solution
A storage appliance is introduced to backup and restore the control execution environment of controller platforms, using persistent memory to store and retrieve application module configurations and state information, ensuring seamless transition and reducing the need for user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardware redundancy is implemented with primary and backup controllers, then control system availability is improved, but user intervention is required to restore configuration when the primary controller fails
Solution Approach 1:
The patent implements self-service by enabling the backup controller to automatically restore the system without user intervention. When the primary controller fails, the backup controller automatically detects the failure, activates its pre-synchronized copy of the application module and execution environment, and takes over control functions autonomously, eliminating the need for manual configuration restoration.
Solution Approach 2:
The patent uses feedback mechanisms where the backup controller continuously monitors the health and synchronization status of the primary controller. Upon detecting a failure, the feedback loop triggers automatic restoration procedures, and the system provides status information about the restoration process, enabling autonomous operation without user involvement.
2Reliability
If the application module is kept in sync with the primary controller, then backup takeover is enabled, but synchronization time and system complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the synchronization process into distinct components: application module code synchronization, runtime state synchronization, configuration parameter synchronization, and data synchronization. Each component is managed separately with appropriate synchronization mechanisms, reducing overall system complexity while ensuring comprehensive backup capability.
Solution Approach 2:
The patent implements continuous synchronization of the application module and its execution environment between primary and backup controllers. This ongoing synchronization process maintains the backup in a ready state without requiring periodic full synchronizations, reducing the total synchronization time and system complexity while ensuring the backup is always current.
3Reliability
If non-volatile memory or RAM retention systems are used to retain the application module, then memory retention is improved, but user intervention is still required when hardware has failed and the application module needs to be replaced
Solution Approach 1:
The patent introduces an intermediary mechanism in the form of a storage appliance that maintains persistent copies of application modules and their execution environments. This intermediary storage system acts as a bridge between the primary and backup controllers, providing a reliable source for automatic restoration when hardware fails, eliminating the need for user intervention even when application modules need to be replaced.
Data Source
AI summary
A method and network control system for an industrial processing facility (IPF) including, a plant-wide network coupling at least one controller platform. The controller platform comprising computing hardware and a memory and at least one application module (AM) contained in the memory. The AM comprising a control application, data, configuration and state information for the controller platform, wherein the at least one controller platform is coupled by an input/output network to I/O devices coupled to field devices that are coupled to processing equipment on a field level of an industrial processing facility (IPF). A storage appliance coupled to the plant-wide network is arranged to receive a copy of the AM contained in the controller platform to a backup application in the storage appliance. The backup application returning the AM back to the controller platform to recover and restore a failed controller platform to normal operation.