Process data synchronization between redundant process controllers

Patent metadata

Field	Value
Publication number	US-2018364673-A1
Application number	US-201816003588-A
Country	US
Kind code	A1
Filing date	Jun 8, 2018
Priority date	Jun 16, 2017
Publication date	Dec 20, 2018
Grant date	—

Abstract

A fault-tolerant industrial control system includes a redundant controller including a first process controller (CP1) including a first processor with a first associated memory, and a parallel connected second redundant process controller (CP2) including a second processor with a second associated memory. A redundancy link is between CP1 and CP2 for sharing data. CP1 and CP2 include logic gates exclusive of any conditional branching for performing data synchronization and calculations including a different logical arrangement for providing each of a digital output (DO), a digital input (DI), an analog input (AI), and an analog output (AO). At least one input/output (IO) module includes a first IO processor including a first memory coupled by a first leg to CP1 and by a second leg to CP2. The IO module is coupled to field devices that are coupled to processing equipment.

First claim

1 . A fault-tolerant industrial control system, comprising:
a redundant controller including a first process controller (CP 1 ) including a first processor with a first associated memory, and a parallel connected second redundant process controller (CP 2 ) including a second processor with a second associated memory; a redundancy link between said CP 1 and CP 2 for sharing data between said CP 1 and said CP 2 ; said CP 1 and said CP 2 comprising logic gates exclusive of any conditional branching for performing data synchronization and calculations including a different logical arrangement for providing each of a digital output (DO), a digital input (DI), an analog input (AI), and an analog output (AO), and at least one input/output (IO) module including a first IO processor including a first memory coupled by a first leg to said CP 1 and by a second leg to said CP 2 , wherein said IO module is coupled to field devices that are coupled to processing equipment.

2 . The fault-tolerant control system of claim 1 , wherein said logic gates for said DO, DI, AI, and AO each include AND gates, OR gates, and XOR gates.

3 . The fault-tolerant control system of claim 1 , wherein said at least one IO module consists of a single IO module.

4 . The fault-tolerant control system of claim 1 , wherein said at least one IO module comprises a first IO module and parallel connected second IO module.

5 . The fault-tolerant control system of claim 1 , wherein said CP 1 and said CP 2 both comprise a programmable logic controller (PLC).

6 . The fault-tolerant control system of claim 1 , wherein said first associated memory and second associated memory are both configured to have stored property data for a plurality of channels including properties comprising scan values, output status data, override flags, and override values organized per said property.

7 . The fault-tolerant control system of claim 1 , wherein said first associated memory and second associated memory are both configured to have stored property data for plurality of channels including properties comprising scan values, output status data, override flags, and override values per said plurality of channels.

8 . A method of process data synchronization between redundant process controllers of a fault-tolerant industrial control system, comprising:
providing a redundant controller including a first process controller (CP 1 ) including a first processor with a first associated memory, and a parallel connected second redundant process controller (CP 2 ) including a second processor with a second associated memory, a redundancy link between said CP 1 and CP 2 for sharing data between said CP 1 and said CP 2 , said CP 1 and said CP 2 comprising logic gates exclusive of any conditional branching for performing data synchronization and calculations including a different logical arrangement for providing each of a digital output (DO), a digital input (DI), an analog input (AI), and an analog output (AO), and at least one input/output (IO) module including a first IO processor including a first memory coupled by a first leg to said CP 1 and by a second leg to said CP 2 , wherein said IO module is coupled to field devices that are coupled to processing equipment; organizing property data for a plurality of channels received including properties comprising scan values, output status data, override flags, and override values in said first associated memory and in said second associated memory, and performing logical operations using said logic gates to generate said DO, said DI, said AI, and said AO.

9 . The method of claim 8 , wherein said logic gates for said DO, DI, AI, and AO each include AND gates, OR gates, and XOR gates.

10 . The method of claim 8 , wherein said at least one IO module consists of a single IO module.

11 . The method of claim 8 , wherein said at least one IO module comprises a first IO module and parallel connected second IO module.

12 . The method of claim 8 , wherein said organizing property data comprises organizing per said property.

13 . The method of claim 8 , wherein said organizing property data comprises organizing per channel for each of said plurality of channels.

Assignees

• Honeywell Int Inc

Inventors

• Van Wensen Aad
• Beerens Anton

Classifications

• G06F11/1658

  Data re-synchronization of a redundant component, or initial sync of replacement, additional or spare unit · CPC title

• G05B2219/24182

  Redundancy · CPC title

• G05B2219/14113

  Fault tolerant objectives for equipment, controller · CPC title

• G05B2219/14014

  Redundant processors and I-O · CPC title

• G05B19/052 Primary

  Linking several PLC's · CPC title