Industrial Control Wake Response Using Preload Values
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Solution Overview
Problem
Industrial control systems face slow response speeds during sleep-wake transitions, which hinder efficiency and output as they transition from energy-saving modes to active modes.
Innovation Solution
The implementation of a method and system that utilize a preload value, retrieved from a memory device, to enhance response speed by determining differences between actual and desired operating parameters, and adjusting control signals accordingly to drive the process system toward desired outputs, leveraging feedback loops and controllers like PID controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the control system enters a sleep mode to save energy, then energy consumption is reduced, but response speed deteriorates when transitioning to active mode
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing a preload value (representing expected sensor data) in memory before the system needs to wake up. When the system transitions from sleep to active mode, this pre-computed value is immediately available, allowing the controller to instantly begin control actions without waiting for actual sensor data, thereby resolving the contradiction between energy saving and fast response.
2Measurement precision
If the control system uses actual sensor data for control decisions, then measurement accuracy is maintained, but response time increases during wake transition
Solution Approach 1:
The patent introduces a preload value as an intermediary between the sleep state and actual sensor data. This intermediary value serves as a temporary substitute that allows the control system to function immediately upon waking, bridging the time gap before actual sensor data is available, thus reducing wake transition time while maintaining the ability to use accurate sensor data when available.
Solution Approach 2:
The system performs preliminary calculation of the preload value (representing expected sensor readings) before wake transition. This pre-computed value is stored in memory and immediately utilized when the system wakes, allowing the controller to start making control decisions without waiting for actual sensor data acquisition, thereby reducing response time while maintaining measurement precision through subsequent sensor updates.
3Productivity
If the control system quickly transitions from sleep to active mode, then productivity is improved, but the likelihood of overshooting desired parameters increases
Solution Approach 1:
The patent implements feedback by continuously monitoring actual sensor data and comparing it with the preload value. When actual sensor data becomes available, the system uses this feedback to adjust control signals and correct any deviations from desired parameters, preventing overshooting while maintaining fast response. The feedback loop ensures that the initial aggressive control actions based on preload values are corrected using accurate sensor measurements.
Data Source
AI summary
One embodiment of the present disclosure describes a method executed by a processor. The method includes receiving a signal associated with a process system transitioning from a reduced energy mode to an active mode. The process system includes devices configured to operate based on data acquired by sensors. The method includes determining a difference between a set of actual data acquired by the sensors and a desired operating parameter of the process system. The method includes reducing the difference using a control algorithm based at least in part on a preload value (e.g., a predetermined value representative of data acquired by the sensors) retrieved from a memory device. The method includes determining a set of control signals based in part on the reduced difference and transmitting the set of control signals to the devices, thereby driving a current operating parameter of the process system toward the desired operating parameter.