Control Logic Preview Mode for Faster Verification
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Solution Overview
Problem
In process control systems, the traditional design and testing process is time-consuming and labor-intensive, requiring iterative cycles of designing, downloading, and testing control logic on a configuration database and live controllers, which hinders quick verification and improvement of control logic.
Innovation Solution
A configuration system that allows users to design, test, and preview control logic before downloading it to a configuration database or process controller, separating the testing of logic and non-logic aspects and enabling preview mode for iterative improvement during the design phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control logic is tested by iterative cycles of designing, downloading to configuration database, and testing on live controllers, then the control logic can be verified, but the process is time-consuming and labor-intensive
Solution Approach 1:
The system performs preliminary testing of control logic in a simulation environment before downloading to the configuration database or live controllers. This preliminary action allows verification of control logic functionality, identification of errors, and validation of control strategies without requiring iterative downloads and live controller testing, thus reducing overall testing time while maintaining verification reliability
Solution Approach 2:
A simulation environment acts as an intermediary between the control logic design stage and the live controller testing stage. This intermediary allows control logic to be tested in a virtual representation of the process control system, providing a safe and efficient medium for verification before deployment to actual controllers, thereby reducing the need for repeated iterative cycles
2Manufacturing precision
If control logic is tested iteratively on live controllers, then accuracy of control logic can be improved, but the complexity of the testing process increases
Solution Approach 1:
The testing process is segmented into distinct stages: initial design, simulation environment testing, configuration database validation, and live controller deployment. Each stage has specific testing objectives and can be completed independently, reducing the complexity of the overall process while maintaining the ability to achieve high control logic accuracy through progressive verification
Data Source
AI summary
The described techniques enable plant personnel to avoid the time and labor-intensive process associated with traditional design systems by enabling users to design, test, and “preview” control logic for controlling a process before downloading the control logic to a configuration database or process controller in the plant. This enables the quick testing and improvement of control logic during the design phase, avoiding the time-consuming iterative process of designing, downloading to a database, propagating to a live controller, and testing on the physical controller. It also separates testing of logic and non-logic aspects of a controller configuration, enabling a user to finish designing the control logic before downloading the configuration to the controller, where she only needs to test non-logic aspects of the configuration.