Backup control mechanism in a distributed control network

• US 6,061,600 A
• Filed: 05/09/1997
• Issued: 05/09/2000
• Est. Priority Date: 05/09/1997
• Status: Expired due to Term

• Current Assignee: I/O Controls Corporation
• Original Assignee: I/O Controls Corporation
• Inventors: Ying, Jeffrey
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US08/854,160
• Time in Patent Office: 1,096 Days
• Field of Search: 395/200.38-200.41, 395/182.09, 395/185.08, 340/825.02, 340/825.07, 340/825.08, 340/825.21, 370/449-457, 370/405, 370/221-224, 709/208-211, 714/11, 714/55, 700/2-4, 700/9, 700/10, 700/79, 700/81, 700/82
• US Class Current: 700/3
• CPC Class Codes: G05B 9/03 with multiple-channel loop, i.e. redundant control systems
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A multi-tier, master-slave control network having redundant backup for a master node in which the slave nodes are provided with means for detecting a failure of the master node and for taking over for the master node in such circumstances. The master node and slave nodes are connected to a common bus. Each of the slave nodes has an uplink transceiver and a downlink transceiver, with the downlink transceiver ordinarily isolated by switches from the common bus. Each of the slave nodes has a timer programmed with a separate failure mode detection time period. When a slave mode fails to receive control messages from the master node for a period exceeding its programmed failure mode detection time period, the slave node takes over for the master node. Because each slave node has a separate failure mode detection time period, a priority is established in which the slave nodes will take over for the master node, and redundant master backup control is provided. A preferred embodiment of the control network has multiple buses, one bus for each tier, and each bus has a master node and a plurality of slave nodes, with each of the slave nodes capable of taking over for the master node on the slave node'"'"'s particular bus.

Claims

1. A control network, comprising:

a common bus;

a master node connected to the common bus; and

a plurality of slave nodes connected to the common bus in a loop configuration with said master node, each slave node comprising

a downlink transceiver isolated from the common bus when the slave node is in normal operation,

an uplink transceiver connected to the common bus, whereby said slave node receives master-control signals over the common bus, and

a failure mode detector;

wherein at least one slave node substitutes itself for the master node by connecting its downlink transceiver to the common bus when the slave node'"'"'s failure mode detector detects a failure of said master node, while said slave node'"'"'s uplink transceiver remains connected to the common bus such that the slave node thereafter receives master-control signals sent by its own downlink transceiver.

2. The control network of claim 1, wherein said failure mode detector comprises a timer connected to said uplink transceiver, said timer timing out a predefined wait period and being periodically reset when said uplink transceiver receives a message signal from said master node.

3. The control network of claim 1 further comprising a second common bus, wherein at least one of said slave nodes functions as a master node for a second set of slave nodes connected in a loop configuration to said second common bus.

4. The control network of claim 3, wherein first and second common buses are connected under control of a single master node when said slave node functioning as a master node for the second set of slave nodes substitutes itself as master node with respect to the first common bus.

5. The control network of claim 1, wherein each slave node further comprises a control unit connected to a plurality of switches, said switches operable to connect or disconnect the downlink transceiver of the slave node to the common bus under the control of the control unit.

6. The control network of claim 5, wherein said switches remain open under normal operation, and wherein said switches are closed by said control unit when the slave node'"'"'s failure mode detector detects a failure of said master node, thereby allowing the slave node to take over as a new master node.

7. The control network of claim 1, wherein each slave node further comprises a first central processing unit connected to the uplink transceiver and a second central processing unit connected to the downlink transceiver, said failure mode detector comprising a timer connected to said first central processing unit.

8. The control network of claim 1, wherein said master node sends periodic polling messages to the slave nodes, and the slave nodes respond to the periodic polling messages with response acknowledgment messages.

9. A method for providing redundant backup master control in a control network which comprises a master node and a plurality of slave nodes connected in a loop configuration, said method comprising the steps of:

sending messages from the master node to the slave nodes over a common bus;

receiving the messages from the master node at each slave node;

monitoring at each slave node an amount of time from receipt of the most recent message from the master node;

substituting one of the slave nodes for the master node when said amount of time reaches a predetermined failure mode waiting period, said substitute master node thereafter concurrently functioning as both a slave node and a master node;

sending messages from said substitute master node to the slave nodes, including itself, over said common bus; and

receiving the messages from said substitute master node at each slave node, including itself.

10. The method of claim 9 wherein at least one of the slave nodes is preprogrammed with the functionality of the master node.

11. The method of claim 9 further comprising, after the step of substituting one of the slave nodes for the master node when said amount of time reaches a predetermined failure mode waiting period, the steps of:

monitoring at each remaining slave node a second amount of time from receipt of the most recent message from the substitute master node; and

substituting one of the remaining slave nodes for the substitute master node when said second amount of time reaches a second predetermined failure mode waiting period, said second predetermined failure mode waiting period being longer than the first predetermined failure mode waiting period.

12. The method of claim 11 wherein:

the step of receiving the messages from the master node at each slave node comprises the step of receiving messages from the master node using an uplink transceiver located at each slave node;

the step of sending messages from the substitute master node to the slave nodes over the common bus comprises the step of sending messages using a downlink transceiver located at the substitute slave node; and

the step of receiving the messages from the substitute master node at each slave node comprises the step of receiving message from the substitute master node using the uplink transceiver located at each slave node.

13. A multi-bus control network with redundant backup control, said multi-bus control network comprising:

a first bus;

a second bus;

a first-tier master node connected to the first bus;

a plurality of first-tier slave nodes connected to the first bus in a loop configuration, each first-tier slave node comprising

a first-tier slave node downlink transceiver isolated from the first bus when the first-tier slave node is in normal operation,

a first-tier slave node uplink transceiver connected to the first bus, whereby said first-tier slave node receives control message signals over the first bus, and

a first-tier slave node failure mode detector;

a plurality of second-tier slave nodes connected to the second bus in a loop configuration, each of said second-tier slave nodes comprising

a second-tier slave node downlink transceiver isolated from the second bus when the second-tier slave node is in normal operation,

a second-tier slave node uplink transceiver connected to the second bus, whereby said second-tier slave node receives control message signals over the second bus, and

a second-tier slave node failure mode detector;

wherein at least one first-tier slave node substitutes itself for the first-tier master node by connecting its first-tier slave node downlink transceiver to the first bus when the first-tier slave node'"'"'s first-tier slave node failure mode detector detects a failure of said first-tier master node;

wherein at least one first-tier slave node has its first-tier downlink transceiver connected to the second bus and functions as a second-tier master node with respect to the second-tier slave nodes; and

wherein at least one second-tier slave node substitutes itself for the second-tier master node by connecting its second-tier slave node downlink transceiver to the second bus when the second-tier slave node'"'"'s second-tier slave node failure mode detector detects a failure of said second-tier master node.

14. The multi-bus control network of claim 13, wherein said first-tier slave node failure mode detector comprises a timer connected to said first-tier slave node uplink transceiver, said timer timing out a predefined wait period and being periodically reset when said first-tier slave node uplink transceiver receives a message signal from said first-tier master node.

15. The multi-bus control network of claim 13, wherein said second-tier slave node failure mode detector comprises a timer connected to said second-tier slave node uplink transceiver, said timer timing out a predefined wait period and being periodically reset when said second-tier slave node uplink transceiver receives a message signal from said second-tier master node.

16. The multi-bus control network of claim 13, wherein each first-tier slave node further comprises a first-tier slave node control unit connected to a plurality of switches, said switches operable to connect or disconnect the first-tier slave node downlink transceiver to the first bus under the control of the first-tier slave node control unit.

17. The multi-bus control network of claim 16, wherein said switches remain open under normal operation, and wherein said switches are closed by said first-tier slave node control unit when the first-tier slave node failure mode detector of the particular first-tier slave node detects a failure of said first-tier master node.

18. The multi-bus control network of claim 13, wherein each first-tier slave node further comprises a second-tier slave node control unit connected to a plurality of switches, said switches operable to connect or disconnect the second-tier slave node downlink transceiver to the second bus under the control of the second-tier slave node control unit.

19. The multi-bus control network of claim 18, wherein said switches remain open under normal operation, and wherein said switches are closed by said second-tier slave node control unit when the second-tier slave node failure mode detector of the particular second-tier slave node detects a failure of said second-tier master node.

20. The multi-tier control network of claim 13, wherein a plurality of the first-tier slave nodes are capable of substituting for the first-tier master node when the first-tier slave node'"'"'s failure mode detector detects a failure of the first-tier master node, each first-tier slave node being programmed with a different waiting period before a failure of the first-tier master node is declared, such that only one first-tier slave node at a given time will detect a failure of the first-tier master node, the different waiting period at each first-tier slave node defining a relative position in a hierarchy by which the first-tier slave node will take over operation as the first-tier master node in case of a failure of the first-tier master node.

21. A multi-tier control network, comprising:

a first common bus;

a first-tier master node connected to the first common bus;

a plurality of first-tier slave nodes connected to the first common bus, each of said first-tier slave nodes capable of receiving commands from said first-tier master node over the first common bus;

a second common bus, said second common bus connected to one of said first-tier slave nodes acting as a second-tier master node; and

a plurality of second-tier slave nodes connected to the second common bus, each of said second-tier slave nodes capable of receiving commands from said first-tier slave node acting as a second-tier master node;

said first-tier slave node acting as a second-tier master node comprising a failure mode detector whereby said first-tier slave node substitutes itself for said first-tier master node in the event of a failure by said first-tier master node, said first-tier slave node connecting said first common bus and said second common bus together to form a single common bus in the event of said failure by said first-tier master node.

22. The multi-tier control network of claim 21 wherein said first-tier master node and first-tier slave nodes are connected in a loop configuration along said first common bus, and wherein said first-tier slave node acting as a second-tier master node and said second-tier slave nodes are connected in a loop configuration along said second common bus.

23. The multi-tier control network of claim 22, wherein said second-tier master node comprises an uplink transceiver and a downlink transceiver, said second-tier master node sending commands with its downlink transceiver over said single common bus and continuing to receive commands with its uplink transceiver over said single common bus after substituting itself for said first-tier master node.

24. The multi-tier control network of claim 21, wherein said first-tier master node comprises a downlink transceiver for sending commands over said first common bus, and an uplink transceiver capable of monitoring said second common bus.