Virtual Hot Standby Control for Fewer Redundant Controllers
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Solution Overview
Problem
Traditional redundant hot standby control systems require a 1:1 or 1:P ratio of main controllers to standby controllers, leading to increased hardware costs and redundancy, as each key process necessitates multiple programmable logic controllers (PLCs) for both main and standby operations, doubling the number of required PLCs and thus the hardware cost.
Innovation Solution
Implementing a redundant hot standby control system with virtual control devices on industrial personal computers (IPCs), where each IPC hosts multiple virtual control devices, allowing one to act as a main and others as standby across the system, connected via industrial Ethernet-based control and field buses, reducing physical device requirements while ensuring reliability through cross-standby functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional redundant hot standby control system uses 1:1 or 1:P ratio of main controllers to standby controllers, then system reliability is improved, but hardware cost increases due to redoubling of controllers
Solution Approach 1:
The patent merges multiple controller functions into a single physical controller by creating virtual control devices. One physical controller hosts multiple virtual controllers, where at least one virtual controller serves as a main control device and others serve as standby control devices. This consolidation reduces the total number of physical controllers while maintaining the redundant hot standby functionality that ensures system reliability.
Solution Approach 2:
The patent implements multi-functionality by enabling a single physical controller to perform multiple roles simultaneously. The controller can host various virtual control devices that function as both main and standby controllers for different control processes. This universal approach allows one physical device to replace what traditionally required multiple dedicated physical controllers.
2Reliability
If traditional redundant hot standby control system configures standby controllers for each key controller, then continuous operation is ensured during faults, but system cost is doubled
Solution Approach 1:
The patent creates virtual copies of controllers through virtualization technology. Instead of requiring physical standby controllers, the system creates virtual control devices that replicate the functionality of main controllers. These virtual standby controllers can be instantiated on the same physical hardware, providing continuous operation capability during faults without duplicating physical devices.
Solution Approach 2:
The patent combines multiple controller instances (main and standby) into a single physical platform. By hosting multiple virtual control devices on one physical controller, the system merges what traditionally required separate physical devices, thereby reducing the total number of physical devices while ensuring continuous operation through virtual redundancy.
Data Source
AI summary
Disclosed is a redundant hot standby control system including K industrial personal computers, with a plurality of virtual control devices being established thereon respectively, at least one of the plurality of virtual control devices being established on each IPC as a main control device; and the other virtual control devices being standby control devices. Each of the standby control devices corresponds to a virtual control device, which serves as the main control device on another IPC, except for the IPC to which the standby control device itself belongs. A procedure, which is the same as that operated on the main control device corresponding thereto, is operated on the standby control device. A control bus of the system is used for connecting a plurality of the M IPCs; and a field bus is used for connecting the M IPCs and a plurality of field devices.

