Distributed Field Device Computing During Industrial Plant Idle Time

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Solution Overview

Problem

Field devices in industrial plants often operate in idle states, leading to inefficient use of processing power and significant power consumption due to their limited tasks, which are typically time-bound.

Innovation Solution

A method for distributed calculation of tasks among field devices, where idle devices receive calculation tasks from a task distribution unit, allowing them to transition into a calculation state, thereby utilizing otherwise unused processing power without affecting the control of the industrial plant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If field devices perform only time-bound control tasks, then control reliability is maintained, but processing power remains idle and power consumption efficiency deteriorates

Engineering Contradiction:

Improvepower consumption efficiencyVSAvoidprocessing power utilization

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

Field devices are designed to perform multiple functions: their primary function is control task execution, but during idle periods they automatically accept and process calculation tasks from the task distribution unit. This multi-functionality allows the same hardware resources to serve both control purposes and general computing purposes, eliminating waste of processing power while maintaining control reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The field devices autonomously monitor their own idle state and automatically transition to processing calculation tasks without requiring external intervention. When the control task completes, the field device self-detects the idle period and self-activates to receive and execute calculation tasks, thereby serving itself to eliminate idle resource waste.

Inventive Principle:

Principle #25Self-service

2Productivity

If field devices remain in idle state during inactive periods, then control task reliability is preserved, but resource utilization efficiency deteriorates

Engineering Contradiction:

Improveresource utilization efficiencyVSAvoidcontrol task reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The operational state of field devices is made dynamic rather than static. Devices automatically transition between three states: control execution state, idle state, and calculation task processing state. This dynamic state management allows the system to adaptively utilize resources based on real-time needs, switching from pure control mode to hybrid mode when calculation tasks are available, thereby improving resource utilization without compromising control reliability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The field devices operate in periodic cycles: executing control tasks during active periods, then transitioning to idle state, and subsequently accepting calculation tasks during idle periods. This periodic alternation between control-only mode and hybrid mode ensures that control tasks are always prioritized while systematically utilizing otherwise wasted idle time for additional processing, improving overall resource efficiency.

Inventive Principle:

Principle #19Periodic action

3Productivity

If field devices process calculation tasks during idle state, then processing power utilization is improved, but device complexity increases

Engineering Contradiction:

Improveprocessing power utilizationVSAvoidoperational state management complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

A task distribution unit is introduced as an intermediary component that manages the distribution of calculation tasks to field devices. This mediator handles the complexity of task scheduling, device state monitoring, and task allocation, thereby shielding individual field devices from complex management logic. The field devices themselves remain relatively simple, relying on the task distribution unit to coordinate their activity during idle periods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Field devices are equipped with simple self-service capabilities to report their idle state to the task distribution unit and automatically accept tasks when idle. This self-service approach minimizes the complexity burden on each device while still enabling sophisticated resource utilization. Each device only needs to monitor its own state and execute simple acceptance/rejection logic, rather than implementing complex scheduling algorithms locally.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12585251B2Method for the distributed calculation of computational tasks

Publication Date: 2026.03.24 SCHNEIDER ELECTRIC IND SAS

AI summary

The invention relates to a method for the distributed calculation of calculation tasks by means of field devices of an industrial plant, wherein a plurality of field devices are coupled to a task distribution unit by means of a data link, the field devices effect a control of the industrial plant in an operating state in each case, at least one of the field devices receives a calculation task from the task distribution unit in an idle state and changes to a calculation state in which the calculation task is processed.