Field Device Method Automation via Execution Recording
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Solution Overview
Problem
Conventional process control systems require repetitive user intervention for executing field device methods, such as maintenance and calibration tasks, as users need to manually enter input values and acknowledge each step, which is time-consuming and prone to errors, especially when similar tasks are performed on multiple devices.
Innovation Solution
An apparatus and method for capturing and recording field device method execution steps, allowing for the playback of these methods using stored data, either online or offline, reducing the need for repeated user input and enabling automated or semi-automated execution, with the capability to detect deviations during playback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual execution of field device methods is used, then users can perform maintenance and calibration tasks, but repetitive user intervention is required which is time-consuming and prone to errors
Solution Approach 1:
The system performs preliminary action by capturing and recording the sequence of operations and user inputs during an initial execution of a field device method. This recorded information is stored for later playback, eliminating the need to manually perform the same steps repeatedly. The preliminary capture phase enables automated reproduction of maintenance and calibration tasks without repeated user intervention.
2Reliability
If manual execution of field device methods is used, then users can interact with each step, but repetitive user intervention increases the risk of errors
Solution Approach 1:
The system applies copying by creating a digital replica of the method execution process. It captures the complete sequence of operations, screen displays, and user inputs, then stores this information for playback. During playback, the system automatically reproduces the recorded steps and inputs, eliminating manual repetition and reducing human error while maintaining operational accuracy.
3Extent of automation
If automated playback of field device methods is implemented, then user intervention is reduced, but the system complexity increases
Solution Approach 1:
The system introduces an intermediary component - a recording and playback module - that acts as a mediator between the user and the field device method execution. This intermediary captures the execution process, stores it, and automatically reproduces it during playback. The intermediary handles the complexity of automation internally while presenting a simple interface to users, effectively bridging manual operation and full automation.
Data Source
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AI summary
A method includes receiving (808) a first request to execute a field device method associated with a process control field device (126a-126n). The method also includes initiating actual execution (818) of the field device method with the field device and/or simulating execution (824) of the field device method. The method further includes recording (820, 826) information associated with the actual or simulated execution of the field device method and recording (820, 826) user input associated with the field device method. In addition, the method includes receiving (808) a second request to play back execution of the field device method, initiating subsequent execution (832) of the field device method, and using the recorded information and the recorded user input during the subsequent execution of the field device method.