Cascaded Configuration Deployment for Field Devices
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Solution Overview
Problem
The deployment of field device configurations in complex industrial process control systems is time-consuming due to the serial nature of block deployment in Fieldbus systems, leading to substantial delays when multiple devices are connected to a single control module assembly.
Innovation Solution
A method for automated cascaded deployment of configuration packages to a set of field devices through control module assemblies and I/O module assemblies, allowing parallel distribution and execution of deployment packages across multiple devices, reducing the time required for configuration setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If blocks are deployed serially from configuration to field devices one block at a time, then deployment accuracy is maintained, but deployment time increases substantially
Solution Approach 1:
The patent segments the deployment process into hierarchical levels: control module assembly level, I/O module assembly level, and field device level. Configuration packages are divided and distributed through these segments in parallel, allowing simultaneous deployment to multiple field devices while maintaining controlled propagation of configuration data through each segment level.
Solution Approach 2:
The patent implements preliminary action by having control module assemblies and I/O module assemblies pre-process and stage configuration packages before final deployment to field devices. Configuration packages are prepared and queued at higher levels, enabling coordinated parallel deployment across multiple devices without overwhelming individual components.
2Adaptability or versatility
If multiple field devices are connected to a single control module assembly, then system integration is improved, but configuration deployment time increases due to serial processing
Solution Approach 1:
The patent adds a dimensional aspect to deployment by introducing hierarchical levels (control module assembly → I/O module assembly → field device) and parallel processing paths. Instead of single-dimensional serial deployment through one device at a time, configuration packages traverse multiple dimensions simultaneously, deploying to numerous field devices through parallel I/O module assembly channels.
Solution Approach 2:
The patent introduces I/O module assemblies as intermediaries between control module assemblies and field devices. These intermediary components receive, stage, and distribute configuration packages to multiple field devices, enabling the control module assembly to manage many devices without direct serial communication with each individual device.
3Reliability
If comprehensive configuration parameters are deployed to each field device, then device functionality is enhanced, but deployment complexity increases
Solution Approach 1:
The patent segments comprehensive configuration packages into smaller, manageable units that are distributed through the hierarchical structure. Each control module assembly and I/O module assembly handles specific portions of the configuration data, breaking down the complex deployment task into simpler sub-tasks that can be executed in parallel without overwhelming individual components.
Solution Approach 2:
The patent implements partial action by deploying configuration parameters in staged portions through the hierarchical levels rather than attempting to deploy all parameters simultaneously to all devices. Each level processes and forwards relevant configuration subsets, enabling comprehensive device functionality to be achieved through cumulative partial deployments rather than a single complex operation.
Data Source
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AI summary
A method and system are disclosed for deploying a configuration in a process control system wherein at least a portion of the configuration is deployed to a set of field devices. Initially the set of deployment packages are stored within a configuration storage. Thereafter, deployment is initiated on the set of deployment packages from the configuration storage. In response to the initiating deployment step, an automated cascaded deployment is commenced to the set of connected field devices. The automated cascaded deployment includes first deploying the sets of deployment packages to a set of control module assemblies. The method furthermore includes second deploying the received portions of the set of deployment packages to a set of I/O module assemblies. The set of I/O module assemblies maintain and pass the received sub-portions of the set of deployment packages to sets of field devices.