Integrated Loop and Valve Control for Low-Latency Process Operation
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Solution Overview
Problem
Process control systems in industrial plants face delays and increased complexity due to the need for multiple devices and communication links, making real-time diagnostics and control loop optimization challenging.
Innovation Solution
An integrated digital process controller that operates locally to perform PID control, diagnostics, and real-time learning, capable of receiving setpoints from remote hosts and adjusting control parameters independently, allowing for quick and efficient control without relying on remote communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple devices and communication links are used for process control, then control functionality is achieved, but system complexity and delays increase
Solution Approach 1:
The patent combines multiple previously separate devices (PID controller, I/P positioner, valve, sensor) into a single integrated digital process controller. This consolidation eliminates the need for multiple communication links between devices, directly reducing system complexity and communication delays while maintaining all necessary control functionalities.
Solution Approach 2:
The integrated controller performs multiple functions that were previously distributed across separate devices: PID control calculations, I/P conversion, valve positioning, and process measurement. This multi-functionality reduces the number of components needed and simplifies the overall system architecture.
2Power
If centralized administrative computing devices are used, then data processing capability is improved, but system complexity and communication requirements increase
Solution Approach 1:
The patent extracts computational capabilities from centralized administrative devices and places them directly in the field controller. The integrated controller now performs PID calculations, diagnostics, and control decisions locally, eliminating the need for complex communication with remote hosts for routine control operations.
Solution Approach 2:
The integrated controller is capable of autonomous operation, performing all necessary control calculations and diagnostics without requiring continuous communication with centralized systems. It serves itself by making local control decisions based on real-time process data.
3Adaptability or versatility
If multiple separate devices are used for control loop operation, then control functionality is achieved, but installation and maintenance complexity increase
Solution Approach 1:
By merging multiple control functions into a single integrated device, the patent simplifies installation (fewer components to install and connect) and maintenance (fewer components to troubleshoot and replace) while preserving all necessary control capabilities.
Data Source
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AI summary
An integrated controller configured to operate in a field includes a network interface module, one or more function modules, and an output module. The network interface module is configured to receive, from a remote host via a communication link, a setpoint for a process variable. The one or more function modules are configured to (i) receive a measurement of a process variable from a field device and (ii) execute logic for a control loop including the field device based at least in part on the measurement of the process variable and the setpoint for the process variable, to generate an output signal independently of the remote host, where the output signal is for controlling the field device. The output module is configured to directly apply the generated output signal to the field device.