Facility Coordinator Translation Layer for Legacy Process Control
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Solution Overview
Problem
Many industrial control systems are antiquated and lack modern features such as cloud connectivity, real-time data analytics, and machine learning, making them inefficient in implementing energy-saving strategies and rapidly varying operational conditions.
Innovation Solution
A system comprising controllable devices, environmental sensors, and a facility coordinator that receives prescriptions from a remote server, translates them into actionable commands, monitors sensor data, and takes corrective actions to maintain environmental and operational constraints, optimizing energy use and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If modern energy strategies are implemented using antiquated control systems, then energy optimization is attempted, but implementation is slow, expensive, or requires hardware changes
Solution Approach 1:
The patent introduces a translation layer (facility coordinator) that acts as an intermediary between modern energy management systems and antiquated control systems. This coordinator translates contemporary control logic into legacy-compatible commands without requiring hardware modifications to the existing control infrastructure, thereby enabling energy optimization while avoiding complex hardware changes
Solution Approach 2:
The system creates a virtual model or representation of the facility's control architecture that mirrors the functionality needed for modern energy strategies. This virtual copy allows implementation of advanced energy management algorithms in software without physically modifying the actual hardware control systems
2Adaptability or versatility
If cloud connectivity and real-time data analytics are added to antiquated control systems, then modern capabilities are achieved, but system complexity and cost increase
Solution Approach 1:
The patent segments the control architecture into distinct functional layers: a legacy control layer that handles basic operations, a translation layer that manages communication protocols, and a modern analytics layer that provides cloud connectivity and real-time data processing. This segmentation allows modern capabilities to be added without integrating them directly into the antiquated control system, thereby reducing overall system complexity
Solution Approach 2:
The facility coordinator serves as an intermediary gateway that handles all cloud connectivity and data analytics functions externally. This mediator allows the antiquated control system to gain modern capabilities through standardized communication interfaces without requiring internal modifications that would increase system complexity
3Stability of the object's composition
If control systems are designed to maintain static process setpoints, then system stability is maintained, but rapid variation of operational variables is not possible
Solution Approach 1:
The patent implements dynamic setpoint adjustment capabilities within the translation layer that allow operational variables to vary rapidly in response to changing conditions. The system maintains stability by using controlled transition mechanisms that adjust setpoints dynamically based on real-time feedback while preventing abrupt changes that could destabilize the legacy control system
Solution Approach 2:
The system enables rapid variation of operational variables by changing control parameters through the translation layer rather than modifying the core control logic. This allows dynamic adjustment of setpoints and operational parameters while maintaining the stability characteristics of the original control system through carefully managed parameter transitions
Data Source
AI summary
Systems and methods for industrial process control coordination and implementation are disclosed. In some embodiments, a facility coordinator may be configured to: receive a facility prescription from a remote server; translate the facility prescription into one or more commands understood by one or more of a plurality of controllable devices; communicate the one or more commands to the one or more controllable devices; receive sensor data from one or more of a plurality of environmental sensors; determine based on the sensor data whether an aspect of an environment or one or more of the controllable devices violates one or more constraints; and in the event operational, safety, or physical constraints are or will soon be violated, determine a corrective action and send corrective action commands to one or more of the plurality controllable devices.