Virtualization Unit for Online Operating System Updates in Process Control
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Solution Overview
Problem
Conventional process control systems in industrial plants cannot be arbitrarily stopped for updates, posing challenges in addressing operating system faults without disrupting continuous operations, and existing methods for updating do not guarantee stable operation on newer systems.
Innovation Solution
A process control apparatus with a virtualization unit that allows for parallel operation of old and new operating systems, enabling online updates by recording and verifying the state of applications and operating systems to ensure seamless transition and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the process control system is stopped to update the operating system, then the operating system can be updated, but the continuous operation of the process control system is disrupted
Solution Approach 1:
The patent applies preliminary action by creating a backup of the current operating system state before performing the update. The backup unit creates a backup image of the current operating system 23a before it is overwritten, allowing the system to restore the original state if the update fails, thus enabling safe updates without disrupting continuous operation
Solution Approach 2:
The patent implements beforehand cushioning by preparing a backup copy of the operating system in advance. The backup image stored in storage unit 62 serves as a safety buffer that protects against update failures, allowing the system to attempt updates without risking continuous operation disruption
2Productivity
If the operating system is updated without stopping the process control system, then continuous operation is maintained, but the stability and reliability of the update process cannot be guaranteed
Solution Approach 1:
The system performs preliminary actions by creating a complete backup image of the current operating system before initiating the update process. This backup is stored in storage unit 62 and can be used to restore the system if the update fails, ensuring update stability while maintaining continuous operation
Solution Approach 2:
The patent uses copying by creating a backup copy of the operating system 23a in the form of a backup image. This copy is stored in storage unit 62 and serves as a safety net, allowing the system to attempt updates without compromising the original stable state, thus guaranteeing update reliability
3Reliability
If a backup of the operating system state is created before updates, then system restoration is enabled, but the time and resources required for backup and verification increase
Solution Approach 1:
The patent extracts only the essential backup information needed for restoration - specifically the backup image of the operating system stored in storage unit 62. This selective extraction of necessary data minimizes backup time and resource requirements while maintaining full restorability capability
Solution Approach 2:
The system creates a simplified copy of the operating system state in the form of a backup image, which can be quickly stored and restored. This copying approach balances the need for complete restorability with the constraint of minimizing backup time and resource consumption
Data Source
AI summary
A process control apparatus includes a virtualization unit configured to operate in hardware, first and second operating systems configured to run in the virtualization unit, an application configured to run in the first operating system, and configured to control an industrial process by communicating with field devices, a recording unit configured to record a first information required for restoration of the application and a second information passed between the first operating system and the application, and a restoration unit configured to use a history of the second information to set the second operating system to the same state as the internal state of the first operating system, and configured to use the first information to restore the application running in the first operating system into the second operating system.