Allen-bradley Company, LLC

Rockwell Automation Technologies Incorporated

William B Cook

Mark A Flood

Brian Alan Batke

James Joseph Kay

Jack Michael Visoky

Scott A Mintz

Mark E Taylor

Bradley J Bittorf

Steven P Richter

Kenneth William Batcher

Robert R Sepsi

Robert D Law

David A Karpuszka

Jack F Toma

Robert D Eaton

D Alan Graham

David E Mohnke

A method for installing embedded firmware is provided. The method includes generating one or more firmware file instances and generating one or more digital certificate instances that are separate instances from the firmware file instances. The method includes associating the one or more digital certificate instances with the one or more firmware file instances to facilitate updating signature-unaware modules with signature-aware firmware or to facilitate updating signature-aware modules with signature-unaware firmware.

Methods for firmware signature

An industrial control system implementing a multi-tasking operating system employs a primary and secondary controller each having a processor and an I/O data table. The processors are configured to execute one or more priority ranked programs. A tracking of changes in the I/O data table of the primary processor is used to independently track changes to controller specific data that has been changed and program specific data that has been changed and to transmit controller specific data that has been changed by any program and program specific data that has been changed only for completed programs to the secondary processor.

Method and apparatus for providing redundancy in an industrial control system

A method and apparatus are disclosed for performing timely execution of periodic tasks in a redundant control system. A secondary controller in the redundant system receives a wakeup time array having at least one wakeup time element corresponding to a periodic task as well as a current time value from a primary controller, and schedules a run time for the periodic task at switchover based on the wakeup time element and the current time value from the primary control module. The secondary controller may further receive a task instance corresponding to the periodic task from the primary control module, and schedule a run time for the periodic task at switchover based on the task instance. In addition, the secondary controller may schedule a run time for the periodic task at switchover based on a default period associated with the periodic task, if no task instance and no wakeup time element were received corresponding to the periodic task.

System and method for periodic task resumption following redundant control system switchover

On-line upgrading of a primary industrial controller is provided through the use of a secondary industrial controller that may assume control of the process controlled by the primary industrial controller. A switch-over of control is orchestrated by a system back-up module that may detect removal of the functional components of the primary industrial controller to initiate the switch-over. Determination of removal of functional modules may be provided by a periodic polling of the functional components on the interconnecting communication link. The system back-up module designates one of the functional modules to poll the system back-up module so that complete coverage of removable components may be had.

Redundant automation controller permitting replacement of components

A redundant industrial controller system has a primary controller backed up by a secondary controller and recovers from a power loss by analyzing the state memories of the controllers to reach a determination of which controller would best be suited to assume primary control status without resorting to arbitrary tie-breaking procedures or race conditions. The rules and their inputs are applied by both controllers which independently make the determination as to which controller should be the primary controller.

Redundant automation controller with deductive power-up

An industrial controller provides a primary controller and a redundant secondary controller and allows switchover between the controllers in the event of a failure in the primary controller. The process of qualification of the secondary controller in which its programming is made to match the primary controller may be inhibited to permit the secondary controller to maintain a clean version of an upgraded program executing on the primary controller. The clean program may be reverted to in the event an upgrading of the program in the primary controller is unsuccessful. Switchover is permitted even though the qualification of the secondary controller is not enabled.

Redundant processor controller providing upgrade recovery

An industrial control system employs a primary and secondary controller each having a processor and an I/O data table. Updating of the secondary processor's I/O data table is accomplished synchronously with execution of the program in the primary processor at a particular point in the program. A tracking of changes in the I/O data table of the primary processor is used to transmit only changes in the I/O table to the secondary processor thereby avoiding undue interruption of the executing program while preserving synchronicity.

Industrial controller with program synchronized updating of back-up

The present invention constitutes a data crossloading system for use with a programmable controller system having primary and secondary (or 'back-up') systems each of which have redundant hardware components and have data structures associated with these components. The present invention further relates to the interconnection of the hardware components and to the processes for providing redundant data structures which enable a secondary or back-up system to rapidly and effectively assume control when a malfunction occurs in a primary control system. Both systems are connected via the same remote data links to common I/O racks which interface to sensing and output devices on the equipment being controlled. Data structure information in the primary system is specially crossloaded to the secondary system so that when a malfunction occurs that shuts down the primary system, the secondary system can begin execution of the same control programs and input and output the same data to the same I/O racks based on up to date data from the primary system. The crossloading of the data is accomplished through the use of special backup modules in both the primary and secondary (backup) control systems connected by a high speed communications link. Communications take place through the use of program utilities which establish a tightly coupled communications network between the primary and secondary systems. Additionally, on-line editing is enabled in stages so that when either control system can not properly execute the edit it is rejected. This system insures that edits can not take place in the primary system without being concurrently implemented in the secondary system.

Programmable controller backup system

A communication circuit sends asynchronous digital signals in parallel to an external device. A first parity circuit in the communication circuit computes a first bit which indicates the parity of the control signals. This first bit is sent to the external device. When the digital signals and the parity bit are received by the external device, a first control signal is produced when each of the received digital signals has the same logic level for a defined period of time. A second parity circuit produces a second control signal when a parity error is found in the received digital signals. An error signal is generated in response to the presence of both the first and second control signals.

Apparatus for detecting parity errors among asynchronous digital signals

A machine is controlled by a system which has a pair of programmable controllers connected in tandem. One controller operates in the active mode governing the operation of the machine, while the other controller is in a backup mode able to assume control of the machine should the active controller fail. Each programmable controller has a backup module through which the two controllers are connected. In order to determine which controller is to be active upon power up, each backup module has an input means for receiving a first active mode request signal from another programmable controller. A means is provided to produce a tie breaker signal at one backup module which indicates that its programmable controller is to operate in the active mode when both programmable controllers simultaneously desire to operate in the active mode. A mode indicator in the backup module designates the active mode when the input means does not receive the first active mode request signal, or when the input means is receiving the first active mode request signal and the tie breaker signal is being produced at that backup module. Otherwise, the mode indicator designates that the programmable controller is to operate in the backup mode. An output means transmits a second active mode request signal to the other programmable controller when the mode indicator designates the active mode.

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Northfield, OH, United States of America

William B Cook