Industrial Asset Stream Analytics for Interdependency-Based Control
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Solution Overview
Problem
Industrial process control systems lack a holistic view of interconnected components, leading to inefficient operations as they do not consider the state of other assets working in concert, resulting in suboptimal performance and inefficiencies.
Innovation Solution
A stream-based processing system that receives data from multiple nodes within an industrial network, cleanses and preprocesses it, and uses analysis engines to model underlying conditions in real-time, enabling adjustments to be made based on a holistic view of the network, potentially using fuzzy logic and decision tables to determine corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a control system monitors and controls each component independently using preset thresholds, then the control logic is simple and responsive, but the system lacks a holistic view of interconnected components leading to suboptimal performance
Solution Approach 1:
The patent merges data from multiple independent control systems into a unified stream-based processing platform. The system collects data streams from various assets (124), aggregates them centrally, and performs holistic analysis that considers interdependencies between components, thereby achieving both comprehensive visibility and coordinated optimization without sacrificing individual component responsiveness.
Solution Approach 2:
The control system is designed with multi-functionality to handle both individual component monitoring and system-wide optimization. The stream-based processing platform can simultaneously perform threshold-based reactive control for individual assets and predictive analytics for the entire industrial process, making the system adaptable to multiple control strategies without requiring separate dedicated systems.
2Productivity
If data from multiple assets is collected and analyzed in real-time to achieve holistic control, then operational efficiency improves, but system complexity and data processing requirements increase
Solution Approach 1:
The patent replaces traditional mechanical control architectures with a software-based stream processing system. Instead of complex hardware interconnections and distributed control logic across multiple devices, the system uses centralized data aggregation and software analytics to achieve holistic control, reducing physical complexity while maintaining or enhancing operational efficiency.
Solution Approach 2:
The stream-based processing platform acts as an intermediary layer between individual assets and the control decision-making process. This mediator aggregates, standardizes, and analyzes data from multiple sources before presenting coordinated control actions, thereby simplifying the overall system architecture by introducing a single point of integration rather than requiring direct complex interconnections between all components.
3Speed
If traditional control systems use preset threshold values for each component, then the response time is immediate, but the system cannot account for underlying conditions or interdependencies between assets
Solution Approach 1:
The system implements multi-level feedback mechanisms: immediate threshold-based feedback for individual asset anomalies and longer-term predictive feedback based on stream processing analytics. The stream processing platform continuously analyzes patterns across multiple data streams and provides feedback about underlying conditions and interdependencies, enabling the control system to respond not only to individual threshold violations but also to emerging system-wide trends and root causes.
Data Source
AI summary
A system includes a first asset disposed at a first location in an industrial system configured to perform one or more operations, a second asset disposed at a second location in the industrial system, and a server device communicatively coupled to the first asset and the second asset. The server device is configured to receive a first set of stream-based data from the first asset, receive a second set of stream-based data from the second asset, identify a first portion of the first set of stream-based data and a second portion of the second set of stream-based data, wherein the first portion and the second portion comprises a same type of data, determine whether the first portion of the first set of stream-based data corresponds to an expected range of values based on the second portion of the second set of stream-based data, and send a command to the first asset to adjust a first set of operations in response to the first portion of the first set of stream-based data not being within the expected range of values.