Process Image Backbone for Transparent Cross-Controller Data Access
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Solution Overview
Problem
Conventional automation systems face challenges in providing universal and transparent data access across different devices and layers, which limits the effectiveness of data analytics and increases latency in control processes.
Innovation Solution
The implementation of a process image backbone that unifies data access from various devices and runtimes, enabling decoupled interactions and providing a unified medium for data access, management, and analytics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If data is transferred from controllers to upper layer (SCADA or MES) for data management and analytics, then data access is provided across automation systems, but data resolution and readiness are reduced, increasing latency and limiting analytics effectiveness
Solution Approach 1:
The patent segments the automation system into multiple hierarchical levels (controller level, upper level, and edge level) with dedicated data processing functions at each level. The edge computing device acts as an intermediate segment that processes data locally before transferring to upper levels, reducing the need to transfer all raw data upward and thereby reducing latency while maintaining data accessibility.
Solution Approach 2:
The edge computing device serves as an intermediary between controllers and upper layer systems (SCADA or MES). It receives data from controllers, performs local processing and analytics, and only transfers processed results upward. This intermediary role reduces latency by handling data locally and reduces bandwidth requirements by filtering data before upward transfer.
2Device complexity
If conventional pyramid structure is used for data transfer from controllers to upper layer, then data management is simplified, but data analytics capability and control optimization effectiveness are limited
Solution Approach 1:
The patent introduces an edge computing layer that segments the traditional pyramid structure into controller level, edge level, and upper level. This segmentation enables distributed analytics processing at the edge level, improving overall analytics effectiveness without significantly increasing system complexity as the edge device acts as a natural intermediate layer.
Solution Approach 2:
The patent adds a new dimensional layer (edge computing layer) to the traditional vertical pyramid structure. This creates a multi-dimensional architecture where data can be processed both vertically (upward to upper levels) and horizontally (locally at edge level), enabling parallel analytics processing that improves productivity without linearly increasing complexity.
3Stability of the object's composition
If static controller logic/configuration is used, then system stability is maintained, but dynamic adaptive changes and post commissioning modifications are not supported
Solution Approach 1:
The patent implements preliminary action by pre-configuring the edge computing device with analytics processing capabilities and data collection functions during system commissioning. This preliminary setup enables the system to perform adaptive changes and modifications later without disrupting the stable controller logic, as the edge device serves as the modification point rather than the controllers themselves.
Solution Approach 2:
The edge computing device acts as an intermediary that absorbs the complexity of dynamic adaptations and configurations. Controller logic remains static and stable, while the edge device handles dynamic parameter adjustments, analytics model updates, and post-commissioning modifications, thereby decoupling stability requirements from adaptability requirements.
Data Source
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AI summary
A system for providing access to locally stored process image data to other devices in an industrial production environment includes a plurality of controller devices and a process image backbone. Each respective controller device comprises the following: a volatile computer-readable storage medium comprising a process image area; a non-volatile computer-readable storage medium; a control program configured to provide operating instructions to a production unit; an input/output component configured to update the process image area during each scan cycle or upon the occurrence of one or more events with process image data items associated with the production unit; and a historian component configured to locally store the process image data items of the process image area as time series data in the non-volatile computer-readable storage medium. The process image backbone provides the plurality of controllers with uniform access to the process image data items of each programmable logic device.