Edge Controller Data Contextualization for Reliable Cloud-Connected Machinery
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Solution Overview
Problem
Existing industrial plant control systems face challenges with cloud-based data processing, including delayed data availability, network reliability issues, increased complexity, and high costs due to network bandwidth usage, as well as the loss of data context during transmission.
Innovation Solution
An edge controller apparatus processes and contextualizes sensor and actuator data locally, creating models that include contextual information and pre-processing the data before sending it to a remote server, thereby reducing the need for extensive cloud-based processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If data is processed completely in the cloud, then centralized processing capability is improved, but data availability time is worsened and network reliability is worsened
Solution Approach 1:
The patent divides the data processing system into two segments: edge processing for local real-time operations and cloud processing for centralized analysis. The edge controller performs initial data processing and contextualization locally, while only processed data is sent to the cloud server, enabling both fast local response and centralized processing capability.
Solution Approach 2:
The edge controller acts as an intermediary between field devices and the cloud server. It receives raw data from sensors/actuators, processes and contextualizes it locally, then transmits the processed data to the cloud server. This intermediary enables local data availability while maintaining cloud connectivity for centralized processing.
2Extent of automation
If all data is sent to the cloud for processing, then cloud processing capability is improved, but network bandwidth consumption is worsened and operational costs are worsened
Solution Approach 1:
The patent extracts and processes only the necessary data at the edge before transmission to the cloud. The edge controller filters, contextualizes, and selects relevant data points, sending only processed and necessary information to the cloud server, thereby reducing network bandwidth consumption while maintaining cloud processing capability for analysis.
Solution Approach 2:
The edge controller performs preliminary data processing, contextualization, and filtering actions locally before data is transmitted to the cloud. This preliminary action reduces the volume and complexity of data sent over the network, lowering bandwidth consumption and operational costs while preserving essential data for cloud-based analysis.
3Extent of automation
If data is transmitted through complex network infrastructure, then cloud connectivity is improved, but network reliability is worsened and system complexity is worsened
Solution Approach 1:
The patent segments the data processing function between edge and cloud, allowing the edge controller to operate autonomously for local real-time processing. This segmentation reduces dependency on complex network infrastructure for critical operations, improving network reliability while maintaining cloud connectivity for centralized processing and analysis.
4Quantity of substance
If raw data is sent to the cloud without local processing, then data completeness is improved, but data context is lost and processing complexity at cloud is worsened
Solution Approach 1:
The edge controller performs preliminary contextualization and enrichment of raw data locally before transmission to the cloud. It adds contextual information, metadata, and processed insights to the data, ensuring that when data reaches the cloud server, it already contains necessary context and structure, reducing the processing complexity required at the cloud level.
Data Source
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Figure 1c
Figure 1d~1e
AI summary
Examples relate to an edge controller apparatus, to an edge controller method, to an edge controller computer program, and to systems comprising an edge controller apparatus. The edge controller apparatus comprises at least one interface for obtaining status data of a plurality of sensors or actuators and for communicating with a remote server. The edge controller apparatus comprises processing circuitry configured to obtain a plurality of units of status data of the plurality of sensors or actuators, the plurality of sensors or actuators being part of machinery or being arranged in an environment of the machinery. The processing circuitry is configured to update at least one model representing the status of the sensors or actuators based on the plurality of units of status data. The processing circuitry is configured to provide the updated at least one model representing the status of the sensors or actuators to the remote server.