Tag Access Switching for Hot Cutover Between Automation Controllers
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Solution Overview
Problem
The existing automation systems face challenges in efficiently migrating from an old system to a new one, particularly due to the complexity of managing tags and maintaining plant operations without interruptions.
Innovation Solution
An information providing system that includes a control device and a managing device. The managing device acquires and compares tag information from both the old and new systems, detects changes in effective tags, and notifies the control device, which then updates the access destination for these tags to the new system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tag assignment and system migration procedures are performed traditionally, then operators can maintain control over the migration process, but the migration time extends beyond the scheduled shutdown period and plant downtime increases
Solution Approach 1:
The patent introduces an HMI server as an intermediary system that manages tag assignments and communicates with both the old and new automation systems. This mediator automatically handles tag information transfer and assignment, eliminating the need for manual operator intervention in tag management while ensuring controlled migration. The HMI server acts as a bridge that coordinates the migration process between systems.
Solution Approach 2:
The patent replaces manual mechanical operations (operators physically changing tag assignments and switching systems) with automated electronic processes. The HMI server automatically retrieves tag information, performs assignments, and manages the migration process through software-based operations, significantly reducing migration time while maintaining reliability through programmed control logic.
2Reliability
If operators manually manage tag assignments during hot cutover, then they can review and assess risks, but human error increases leading to plant shutdown
Solution Approach 1:
The HMI server performs self-service by automatically retrieving tag information from the old system, assigning tags to the new system, and managing the migration process without requiring manual operator intervention for each tag. The system autonomously handles the complex task of tag management, reducing human error while maintaining operational control through automated procedures.
Solution Approach 2:
The patent implements feedback mechanisms where the HMI server continuously monitors tag assignment status, communicates with both old and new systems to verify successful migration, and provides status information to operators. This feedback loop ensures that tag assignments are correctly performed and allows for verification without requiring manual checking of each tag, reducing errors while maintaining oversight.
3Reliability
If both old and new HMIs are operated simultaneously during migration, then operators can monitor both systems, but the number of operations increases and human error likelihood increases
Solution Approach 1:
The patent merges the monitoring functions of both old and new HMIs into a unified HMI server interface. The HMI server consolidates tag information from both systems and presents a single integrated view to operators, eliminating the need to switch between separate HMI interfaces. This merging reduces the number of operations required while maintaining comprehensive monitoring capability through a unified system.
Data Source
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AI summary
An information providing system includes a control device and a managing device. The managing device includes an acquiring unit that receives first tag information regarding a first tag set to a first component of a first controller from a first system, and receives second tag information regarding a second tag set to a second component of a second controller from a second system; and a change notification unit that detects whether an effective tag has changed from the first tag to the second tag based on the first tag information and the second tag information, and that notifies the control device of a detection result. The control device includes a setting change unit that changes an access destination to the effective tag to the second controller based on the detection result.