Field Device Batch Preparation Through Scope-Based Configuration
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Solution Overview
Problem
The traditional process of preparing devices on a plant floor is time-consuming and labor-intensive, requiring manual correlation and configuration of each device, which can take several man-months or even years for large installations and is prone to errors.
Innovation Solution
A method and system that utilize a computing device to display a user interface providing a visual summary of installed field devices, allowing batch configuration updates through predefined device preparation scopes, enabling parallel processing and reducing setup time by correlating and configuring multiple devices simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual device configuration is performed one device at a time, then each device can be individually configured with attention to detail, but the overall preparation time becomes excessively long and labor-intensive
Solution Approach 1:
The patent segments the device configuration process into distinct phases: device discovery, correlation matching, scope selection, and parallel configuration execution. By dividing the monolithic manual process into these manageable segments, the system can apply different processing modes (sequential for matching, parallel for configuration) to different phases, thereby improving overall efficiency while maintaining quality.
Solution Approach 2:
The system performs preliminary actions by automatically discovering devices on the network, pre-correlating them with database entries using matching rules, and pre-selecting configuration scopes before the actual configuration execution. This preliminary preparation eliminates the need for manual device-by-device configuration during the execution phase, enabling parallel processing and significantly reducing total preparation time.
2Reliability
If a user manually configures each device individually through the user interface, then configuration accuracy can be maintained, but the complexity of the preparation process increases and requires significant user time and effort
Solution Approach 1:
The system implements self-service by automatically performing device discovery, correlation matching with database entries, and configuration execution without requiring manual user intervention for each device. The matching rules engine automatically pairs physical devices with database entries, and the system autonomously executes configuration commands in parallel, reducing user burden while maintaining reliability through automated validation.
Solution Approach 2:
The patent introduces an intermediary correlation database that acts as a mediator between physical field devices and the configuration management system. This intermediary layer stores device identifiers, matching rules, and correlation data, enabling automated matching and reducing the complexity of direct device-to-configuration mapping. The intermediary structure simplifies the overall process by decoupling device identification from configuration execution.
3Productivity
If parallel batch configuration is implemented, then device preparation time is significantly reduced, but the risk of errors and mis-configurations may increase
Solution Approach 1:
The system implements feedback mechanisms by continuously monitoring the configuration execution process, tracking the status of each device being configured in parallel, and providing real-time updates on preparation progress. The system can detect errors during parallel execution and implement corrective actions, ensuring that reliability is maintained even as productivity increases through parallel processing.
Solution Approach 2:
The patent applies beforehand cushioning by performing validation checks and error prevention measures before parallel configuration execution begins. The system validates device correlations, verifies configuration parameters, and prepares error handling protocols in advance, creating a protective buffer that prevents errors from propagating during parallel execution. This proactive error prevention maintains high reliability while enabling fast parallel processing.
Data Source
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Figure 2B~2B(1)
AI summary
A method and a system for preparing a plurality of installed field devices for operation in a process control network. In some embodiments, a computing device provides a visual summary of the installed field devices to a user via a user interface. A configuration database stores predefined device preparation scopes, each scope being indicative of one or more of the installed field devices. Based on a user selection of one or more predefined device preparation scopes in the user interface, the computing device implements each of the predefined device preparation scopes by, among other things, retrieving configuration information from the configuration database for each installed field device indicated by each predefined device preparation scope and transmitting the information to each respective installed field device for updating the device configuration.