Virtual Controller Coupling Across Edge Devices for Redundancy
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Solution Overview
Problem
In automation environments, the failure of a single computing unit hosting multiple virtual controllers leads to the shutdown of large parts of an industrial machine or plant, which is unacceptable, and existing solutions do not effectively address the need for reliable cross-device coupling and synchronization of virtual controllers for redundancy.
Innovation Solution
A two-stage coupling method is employed, first at the device level and then at the controller level, ensuring that virtual controllers on different devices pair with each other while avoiding pairing on the same hardware, using device and control coupling applications to establish redundancy pairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple virtual controllers are run on a single computing unit, then resource utilization is improved, but reliability deteriorates because all virtual controllers fail when the computing unit fails
Solution Approach 1:
The system segments virtual controllers across multiple physical computing units (edge devices). Each virtual controller is assigned to a specific edge device, creating spatial separation. This segmentation ensures that failure of one edge device does not affect virtual controllers on other devices, thus maintaining reliability while still achieving resource utilization benefits through virtualization on each device.
Solution Approach 2:
The patent implements local quality by creating device-level pairing where each edge device has specific redundancy relationships with designated partner devices. The coupling application establishes localized redundancy pairs between specific devices rather than universal coupling, allowing each device to have tailored redundancy arrangements that optimize both resource utilization and reliability for local operations.
2Reliability
If virtual controllers are coupled for redundancy across different devices, then reliability is improved, but device complexity increases due to the need for pairing mechanisms
Solution Approach 1:
The patent merges the device-level coupling and controller-level coupling into a unified two-stage process. The coupling application first establishes device-level pairs, then automatically proceeds to controller-level pairing within those device pairs. This merging of operations simplifies the overall complexity by providing a systematic, automated approach rather than requiring separate manual configurations for each level.
Solution Approach 2:
The system performs preliminary action by establishing device-level coupling first before proceeding to controller-level coupling. This preliminary device pairing creates a structured foundation that simplifies subsequent controller pairing, as controllers only need to pair within already-established device pairs. This staged approach reduces overall complexity by breaking down the pairing process into manageable, sequential steps.
3Ease of operation
If automatic pairing is implemented, then ease of operation is improved, but network load increases due to pairing communication
Solution Approach 1:
The patent extracts the pairing communication process into a dedicated, time-limited phase separate from normal operational communication. The coupling application performs device-level pairing first, establishing connections before controllers begin their pairing process. By separating these pairing phases from ongoing operational traffic, the network load is concentrated in specific initialization periods rather than continuously impacting operational performance.
Solution Approach 2:
The system implements self-service through automatic pairing mechanisms where the coupling application autonomously performs device-level pairing and triggers controller-level pairing without manual intervention. The controllers automatically search for and pair with partners within their device pairs, and the system autonomously manages synchronization and failover. This automation improves ease of operation while the efficient, targeted nature of the automatic processes minimizes unnecessary network traffic.
Data Source
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AI summary
The invention relates to a method for coupling at least two virtual controllers (A.1, A.2, A.3, B.1, B.2, B.3) provided on different devices, in particular edge devices (A, B), for redundant operation, in which a two-stage coupling is carried out, comprising a coupling (4) at the device level and a subsequent coupling (5) at the controller level, wherein, in the coupling (4) at the device level, a device (A, B) on which at least one virtual controller (A.1, A.2, A.3, B.1, B.2, B.3) is provided is coupled with at least one further device (A, B) on which at least one further virtual controller (A.1, A.2, A.3, B.1, B.2, B.3) is provided, and in the coupling (5) at the controller level, a virtual controller (A.1, A.2, A.3, B.1, B.2, B.3) which is provided on one of the devices (A, B) coupled at the device level is provided for and/or will be, with at least one further virtual controller (A.1, A.2, A.3, B.1, B.2, B.3), which is provided on at least one other of the devices (A, B) coupled at the device level. Furthermore, the invention relates to a computer program, a computer-readable medium and a device, in particular an edge device.