Embedded Historian Proxies for Industrial Data Integration
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Solution Overview
Problem
Conventional industrial control system architectures are inefficient in seamlessly exchanging data between various components of an enterprise, leading to inefficiencies in data collection and integration, particularly in complex industrial automation systems where real-time data is required for optimization and compliance with regulations.
Innovation Solution
The implementation of embedded historians that function as proxy components, enabling efficient data collection and integration across an organizational hierarchy by acting as clients/servers, utilizing a locator component to automatically detect and collect historian data, and employing a distributed and scalable framework for data historian functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional PC-historians are applied on the back-end of system design with loose coupling, then data collection architecture is simplified, but data collection efficiency and identification of captureable data are reduced
Solution Approach 1:
The patent segments the historian functionality into distributed micro-historians embedded at different levels of the control architecture (controller level, plant level, enterprise level) rather than using a single centralized back-end historian. This segmentation enables each micro-historian to independently collect and manage data locally, improving data collection efficiency while maintaining architectural simplicity through modular deployment.
Solution Approach 2:
The patent introduces a new dimensional approach by embedding historians horizontally across multiple levels of the control architecture (controller, plant, enterprise) rather than stacking them vertically in a traditional back-end configuration. This dimensional change enables parallel data collection pathways and improves overall system productivity without increasing complexity.
2Reliability
If proprietary softwares are employed to supply controllers with historic data, then data collection capability is enhanced, but system costs and complexity are increased
Solution Approach 1:
The patent creates a universal micro-historian component that can be deployed at multiple levels of the control architecture and serves multiple functions: local data collection, historical data storage, real-time data processing, and compliance reporting. This multi-functional approach enhances data collection capability while eliminating the need for multiple proprietary software solutions, thereby reducing overall system complexity.
Solution Approach 2:
Each micro-historian is designed to be self-configuring and self-managing, automatically detecting available data sources, configuring data collection parameters, and managing local storage resources without requiring complex proprietary software installations or manual configuration. This self-service capability enhances data collection reliability while minimizing system complexity.
3Stability of the object's composition
If conventional control system architectures are used, then system stability is maintained, but seamless data exchange between enterprise components is prevented
Solution Approach 1:
The patent introduces dynamic data exchange capabilities by enabling micro-historians to adaptively connect to multiple data sources and destinations at different hierarchical levels. The system dynamically routes data between controllers, plants, and enterprise systems based on real-time requirements, maintaining system stability through controlled interfaces while enabling versatile data exchange across the enterprise architecture.
4Productivity
If real-time data collection from global manufacturing sites is implemented, then productivity optimization is enabled, but data integration efficiency is reduced
Solution Approach 1:
The patent implements preliminary action by having micro-historians continuously pre-process and prepare data locally at the source before it needs to be exchanged with other system levels. Data is collected, validated, and formatted in advance, reducing the time required for data integration when real-time exchange is required and enabling immediate productivity optimization without integration delays.
Data Source
AI summary
Systems and methods that enable historians (e.g., micro-historians) to function as proxies, to supply plant level data, (e.g., history data) back to the controllers. Accordingly, typically such micro historians can function as clients/servers, to provide higher level data to the controllers (e.g., from third part databases). The historians can create a proxy that image an object on a server associated with controllers (e.g., programmable logic controller.) Such objects can contain data; pieces of code; attributes; operations or combinations thereof, for example.