Hardware redundancy design is a core means of ensuring high reliability and stability in autonomous and controllable industrial computers. It achieves fault isolation, rapid recovery, and continuous operation through multi-level redundancy mechanisms. The design must start with key modules such as power supply, processor, storage, communication, and heat dissipation, combining requirements for independent and controllable technologies to build a complete fault-tolerant system.
Power supply module redundancy is the fundamental guarantee for autonomous and controllable industrial computers. A dual-power parallel design is adopted, with the primary and backup power supplies powered by independent circuits. When the primary power supply fails, the backup power supply can seamlessly switch within milliseconds, ensuring uninterrupted system power. The power supply module must support hot-swapping, allowing online replacement of the faulty power supply without interrupting system operation. Furthermore, the power management chip must integrate overvoltage, overcurrent, and short-circuit protection functions to prevent hardware damage under abnormal operating conditions. Under the requirement of independent controllability, the power supply module must use domestically produced components and pass domestic certification to ensure supply chain security.
Processor redundancy design is achieved through a dual-core lockstep or primary/backup CPU architecture. In dual-core lockstep technology, two processor cores execute the same instructions and compare the results in real time. In case of an anomaly, the system immediately switches to the backup core, making it suitable for high-security fields such as aerospace. The master-slave CPU architecture uses asynchronous redundancy. The master CPU is responsible for real-time control, while the backup CPU continuously synchronizes the master system's state and quickly takes over via hardware triggering in case of failure. Autonomous and controllable industrial computers must use domestically produced processors, such as Phytium and Loongson, and optimize the kernel scheduling algorithm to ensure instruction continuity during redundancy switching.
Storage redundancy design is centered around RAID arrays and dual storage controllers. RAID 1 achieves real-time data synchronization through mirroring backup, ensuring data access is not affected by the failure of any disk. RAID 5 uses distributed parity bits, allowing data recovery through algorithms in case of single disk failure. The dual storage controller design manages disks through independent channels; in case of master controller failure, the backup controller automatically takes over storage tasks. Under the requirement of independent controllability, storage media must use domestically produced solid-state drives or hard disk drives, and integrate encryption modules to prevent data leakage.
Communication module redundancy is achieved through dual network card bonding and redundant ring networks. Dual NIC bonding technology virtualizes two physical NICs as a single logical interface, automatically switching links in the event of a NIC failure to ensure network continuity. Redundant ring networks employ a ring topology, such as the PROFINET ring network; when a link segment is interrupted, data is transmitted via the reverse path to maintain communication. Autonomous and controllable industrial computers must support domestic communication protocols, such as Huawei's industrial Ethernet protocol, and integrate a hardware acceleration engine to improve redundancy switching speed.
Cooling redundancy design is achieved through dual-fan modules and heat pipe technology. The dual fans are connected in parallel or series; if the primary fan fails, the backup fan immediately starts to maintain cooling capacity. Heat pipe technology uses phase change materials to efficiently conduct heat, reducing reliance on fans. Under the requirement of independent controllability, the heat dissipation material must use domestically produced graphene or copper-based composite materials, and the airflow design must be optimized through simulation to ensure stable system operation in high-temperature environments.
The verification of hardware redundancy design must undergo a rigorous testing process. The redundancy testing includes simulating power supply, processor, and storage module failures to verify if the system switching time meets standards; environmental adaptability testing to evaluate the reliability of the redundancy mechanism under extreme conditions such as high temperature, high humidity, and vibration; and long-term stability testing, monitoring the failure rate of redundant modules through continuous operation for thousands of hours. The autonomous and controllable industrial computer also needs to pass domestic certification to ensure that all hardware components meet the requirements for technological self-reliance.
The hardware redundancy design of the autonomous and controllable industrial computer achieves a balance between high reliability and security through multi-level redundancy mechanisms in power supply, processor, storage, communication, and heat dissipation, combined with domestically produced components and independent technologies. This design not only meets the stringent requirements for system stability in key fields such as industrial control and aerospace, but also provides solid support for the independent and controllable development of my country's information technology industry.
