Software TSN Agent for Legacy Controller Time Synchronization
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Solution Overview
Problem
Industrial automation systems face challenges in migrating traditional devices to support Time-Sensitive Networking (TSN) and achieving accurate time synchronization, as existing solutions rely on costly hardware components like FPGA-based cards, which are cumbersome to integrate and increase overall costs.
Innovation Solution
A software-based TSN agent is installed in legacy devices, utilizing two network interfaces to segregate TSN and non-TSN traffic, enabling deterministic message delivery through soft synchronization techniques and Kalman Filters to minimize offset variations, eliminating the need for expensive hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If FPGA-based hardware synchronization cards are integrated with legacy controllers to improve time synchronization accuracy, then synchronization precision is improved, but device cost and integration complexity increase
Solution Approach 1:
The patent replaces hardware-based FPGA synchronization cards with a software-based TSN agent that runs on the existing controller's processor. This substitution eliminates the need for additional hardware components while achieving the same time synchronization functionality, thereby reducing device complexity and integration requirements while maintaining synchronization accuracy
Solution Approach 2:
The software TSN agent replicates the time synchronization functionality of expensive FPGA hardware cards through software implementation. By copying the essential synchronization logic and algorithms into software form, the system achieves comparable precision without requiring costly hardware components, thus resolving the contradiction between precision and cost/complexity
2Measurement precision
If FPGA-based hardware synchronization cards are added to legacy controllers to achieve accurate time synchronization, then time synchronization accuracy is improved, but overall solution cost increases
Solution Approach 1:
The patent uses software, which is significantly cheaper than FPGA hardware cards, to achieve time synchronization. The software TSN agent can be deployed and updated without hardware replacement, reducing both initial costs and long-term maintenance expenses while maintaining the required synchronization accuracy for industrial applications
Solution Approach 2:
By substituting expensive FPGA hardware with software-based synchronization, the patent eliminates the need for costly hardware components. The software agent leverages the existing controller's processing capabilities, thereby achieving accurate time synchronization at a fraction of the cost of hardware-based solutions
3Measurement precision
If hardware synchronization cards are integrated with existing controllers to improve TSN capability, then time synchronization capability is improved, but ease of operation deteriorates due to required design changes and system validation
Solution Approach 1:
The software-based TSN agent eliminates the need for physical hardware integration, design changes, and extensive system validation. The agent can be installed and configured through software deployment processes, which are inherently simpler and less intrusive than hardware integration, thereby improving ease of operation while maintaining synchronization capability
Solution Approach 2:
The software TSN agent is designed to be self-contained and self-configuring, requiring minimal external intervention for installation and operation. It can automatically interface with the existing controller architecture and TSN network without requiring complex integration procedures, thus enhancing ease of operation compared to hardware card integration
Data Source
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AI summary
The present invention discloses a controller configured to communicate over a network in a process plant, wherein the network comprises one or more native TSN devices. The controller comprises one or more process applications for controlling one or more processes in the process plant, wherein the one or more process applications includes plurality of tags corresponding to one or more process variables of the one or more processes in the process plant, a software TSN agent for receiving and transmitting packets associated with the one or more process applications on the controller, wherein the software TSN agent is configured to segregate packets associated with the one or more process applications for processing the packets in at least one of a TSN communication mode and a non-TSN communication mode; and a first network interface dedicated for TSN communication and a second network interface dedicated for non-TSN communication.