Actuator-Sensor Proximity Detection Using Process Test Patterns
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Solution Overview
Problem
The manual engineering outlay required for linking measured values of different field devices in process industry installations is cumbersome, and existing methods do not efficiently automate the determination of proximity relationships between actuators and sensors.
Innovation Solution
An arrangement and method that automate the determination of proximity relationships between an actuator and sensors by having the actuator influence the process according to a predefined test pattern, search for the predefined test pattern in sequences of measured values from sensors, and identify the sensor with the best response quality and response time as the sensor with the greatest operative proximity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual engineering is used to link measured values of different field devices, then the linking can be established with existing tools and methods, but the engineering outlay is cumbersome and time-consuming
Solution Approach 1:
The system performs automatic self-identification and self-linking. Sensors and actuators automatically determine their operative proximity relationships through test pattern execution and measured value analysis, eliminating the need for manual engineering configuration. The field devices serve themselves by autonomously establishing the functional relationships required for operation.
Solution Approach 2:
The system changes the operational parameters of the actuator (using test patterns that vary process influencing actions) to elicit measurable responses from sensors. By analyzing how different parameter changes propagate through the system, the automatic linking method identifies functional relationships without manual configuration.
2Extent of automation
If existing methods are used to determine proximity relationships, then the process can be automated to some extent, but the determination of which sensors are truly in operative proximity remains inefficient
Solution Approach 1:
The system uses feedback from sensor measured values to verify actuator test patterns. Sensors that are truly in operative proximity will produce measured values that correspond to the test pattern actions, providing feedback confirmation of the functional relationship. This feedback mechanism ensures accurate identification of proximate sensors.
Solution Approach 2:
The system performs preliminary testing by executing test patterns before finalizing the linking. This preliminary action allows the system to pre-identify which sensors respond appropriately to actuator actions, ensuring accurate proximity determination before operational linking is established.
3Ease of operation
If manual linking is performed in the management system, then the process communication can be planned, but the values require manual setup of input/output cards and process images
Solution Approach 1:
The system automatically generates the process communication configurations, input/output card settings, and process image definitions. Field devices self-identify their relationships and the system automatically creates the necessary communication infrastructure, eliminating manual setup requirements and reducing device complexity.
Data Source
AI summary
A method for determining neighborhood relationships between an actuator and sensors that interact with the an actuator in an installation for controlling a technical process and that communicate with the actuator, wherein the actuator influences the process and the sensors capture measured values of process variables, where the actuator influences the process in accordance with a predefined test pattern, searches for the predefined test pattern in sequences of measured values received from the sensors as responses to the test pattern, and identifies the sensor whose response best satisfies a predefined quality criterion in terms of response quality and response time as the sensor with the greatest operative proximity to the actuator.