Analytical Server Integrated in Process Control Network
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Solution Overview
Problem
Traditional process control systems face inefficiencies and responsiveness issues due to the layered approach of data collection and analysis, which can take significant time and requires operator intervention, especially when handling computationally expensive algorithms like adaptive control techniques and model predictive control, leading to challenges in supporting multiple control loops simultaneously.
Innovation Solution
Integrating an analytical server within the real-time control device to perform computationally expensive analyses directly, allowing for fast and efficient data analysis and model generation without compromising control operations, enabling asynchronous execution and prioritization of algorithms to manage CPU resources effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data collection and analysis are performed using a layered approach in traditional process control systems, then control operations can be maintained, but analysis time increases significantly and operator intervention is required
Solution Approach 1:
The patent merges the analytical server and real-time control device into a single integrated system. The analytical server is integrated within the real-time control device, allowing data collection, analysis, and control operations to occur in the same device without layering, thereby reducing analysis time while maintaining control reliability
Solution Approach 2:
The patent introduces an analytical server as an intermediary component that handles computationally expensive algorithms separately from the real-time control routines. This intermediary processes data asynchronously and provides results to control routines, reducing the time burden on control operations while maintaining reliability
2Measurement precision
If computationally expensive algorithms like adaptive control techniques are implemented, then control accuracy improves, but system responsiveness deteriorates
Solution Approach 1:
The patent segments the control system into distinct functional components: real-time control routines that require fast responsiveness and analytical algorithms that require computational power. The analytical server handles the computationally expensive adaptive control techniques and model predictive control separately, allowing these algorithms to improve control accuracy without slowing down the real-time control loop responsiveness
Solution Approach 2:
The patent implements dynamic execution modes where the analytical server can operate asynchronously and prioritize different algorithms based on system needs. Control routines can request analytical processing at different priority levels, allowing the system to maintain responsiveness while periodically applying computationally intensive algorithms to improve control accuracy
3Adaptability or versatility
If multiple control loops are supported simultaneously, then system versatility improves, but computational resource requirements increase
Solution Approach 1:
The patent creates a universal analytical server that can service multiple different types of control loops simultaneously. The analytical server provides a common platform for running various analytical algorithms (adaptive control, model predictive control, diagnostics) that can be applied to multiple control loops, increasing system versatility while efficiently managing computational resources through shared infrastructure
Data Source
AI summary
A process control system integrates the collection and analysis of process control data used to perform certain computationally expensive process control functions, like adaptive model generation and tuning parameter generation, in the same control device in which one or more of the process control routines are implemented, to thereby provide for faster and more efficient support of the process control routines. This system replaces a layered approach using multiple processing devices by integrating an analytical server which performs computationally expensive analyses used by one or more control routines directly into the real-time control device in which the one or more control routines are located. This integration provides the ability to analyze large quantities of data for multiple process loops controlled by a particular device in a fast and efficient manner.