Industrial Control Load Margin Analysis for Abnormality Detection
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Solution Overview
Problem
Industrial control systems face challenges in accurately determining the processing margin for analysis tasks, which affects the ability to collect and analyze data efficiently, leading to potential production inefficiencies due to incorrect detection of abnormalities.
Innovation Solution
An industrial control system and assistance apparatus that calculate and manage processing loads for different numbers of analysis data, allowing for the extraction of tasks dependent on data quantities, enabling the secure acquisition of necessary data within allowable margins while maintaining reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of analysis data pieces is increased to improve abnormality detection accuracy, then the processing load on the industrial control apparatus increases, reducing the available margin for control tasks
Solution Approach 1:
The patent segments the processing load calculation into two distinct parts: control task load (independent of data quantity) and analysis task load (dependent on data quantity). This segmentation allows independent calculation and management of each load component, enabling precise determination of the margin available for analysis tasks without affecting control task reliability.
Solution Approach 2:
The patent calculates the processing load for analysis tasks based on different numbers of data pieces to determine the optimal amount of data that can be processed within the available margin. This allows the system to utilize the maximum possible data quantity without exceeding control reliability requirements, effectively performing partial action that optimizes the trade-off between detection accuracy and control safety.
2Loss of information
If more analysis tasks are executed to collect necessary data for abnormality detection, then the processing time required increases, reducing the margin for control tasks
Solution Approach 1:
The patent performs preliminary calculation of processing loads for different data quantities before actual execution. By pre-calculating the time requirements for analyzing different numbers of data pieces and comparing them against the available margin, the system determines the optimal data quantity in advance, avoiding excessive data collection that would consume unnecessary control cycle time.
3Quantity of substance
If the industrial control apparatus processes a large number of data pieces for analysis, then the processing capability is overwhelmed, reducing the margin for executing control tasks
Solution Approach 1:
The patent implements a feedback mechanism where the calculated margin information is provided back to the analysis task configuration. This feedback allows operators to adjust the number of data pieces to be analyzed based on the calculated margin, ensuring that analysis tasks are configured within the processing capabilities of the control apparatus, thereby maintaining control task execution efficiency.
Data Source
AI summary
An industrial control apparatus that causes a common processing unit to execute a first execution task for executing processing that does not depend on the number of pieces of data and a second execution task for executing processing that depends on the number of pieces of data, and an assistance apparatus are included. The industrial control apparatus calculates a control load amount of a processing unit incurred by executing the first execution task, and extracts the second execution task from the first and second execution tasks. The assistance apparatus calculates a processing load amount of the processing unit according to the type of the extracted second execution task for the number of pieces of analysis data, and using this processing load amount and the control load amount, calculates a margin of processing that indicates a degree of remaining processing capability of the processing unit.