Background Diagnostic Data Caching in Process Control Systems
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Solution Overview
Problem
In process control systems, diagnostic data from field devices is not readily available for use by control or display applications, often requiring specialized software that can delay communication and consume communication bandwidth, especially for real-time process signals.
Innovation Solution
A method is introduced to communicatively couple a process control field device to a process controller via an input/output device, obtaining a device tag to configure the I/O device to retrieve and cache device diagnostic data, and provide it to applications, using bandwidth not required for real-time communications, allowing asynchronous or low-priority polling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If specialized diagnostic software is used to retrieve device diagnostic data, then diagnostic data becomes available for use, but communication bandwidth is consumed and delays occur for real-time process signals
Solution Approach 1:
The system performs preliminary configuration by obtaining device tags and setting up I/O devices to retrieve diagnostic data before runtime operations. This preliminary setup enables diagnostic data to be automatically collected and cached without requiring specialized software during real-time operations, thus avoiding bandwidth consumption and delays during critical process control communications
2Loss of information
If specialized diagnostic software is used to retrieve device diagnostic data, then diagnostic data becomes available for use, but communication delays occur for real-time process signals
Solution Approach 1:
The system configures I/O devices and establishes diagnostic data retrieval mechanisms in advance during system setup or device initialization. This preliminary configuration ensures that diagnostic data collection is already in place and does not interfere with real-time process control communications during operation, eliminating communication delays
Solution Approach 2:
The I/O device serves as an intermediary between the field device and the control system. It is configured to automatically retrieve and cache diagnostic data from field devices, acting as a mediator that separates diagnostic data collection from real-time process control communications, thus preventing delays in critical signal transmission
3Loss of information
If device diagnostic data is collected in real-time, then data availability is improved, but communication bandwidth required for real-time process control is reduced
Solution Approach 1:
The system performs preliminary configuration of I/O devices to collect and cache diagnostic data during system setup or device initialization phases. This advance preparation ensures diagnostic data is readily available without requiring continuous real-time bandwidth allocation, thus preserving communication resources for critical real-time process control operations
Solution Approach 2:
The I/O device acts as an intermediary that handles diagnostic data collection separately from the main real-time control communication path. By configuring the I/O device to automatically retrieve and cache diagnostic data, the system separates these functions, ensuring that diagnostic data collection does not compete for bandwidth with real-time process control signals
Data Source
AI summary
In a method and system, a device tag allows automatic configuration of a process control system to download and cache device diagnostic data associated with one or more process control field devices. The device diagnostic data are downloaded and cached using bandwidth not otherwise required for real-time process control communications. The device diagnostic data may be polled asynchronously and/or according to a low priority, background task. The device diagnostic data include one or more non-static parameter values. The cached parameter values may be used in display routines, control routines, or any routine for which the update frequency is sufficient. Each cached parameter value may also have associated with it a status.