Mediated Information Collection for Process Control Networks
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Solution Overview
Problem
Existing process control systems face challenges in collecting consistent information about components without disrupting normal operations, leading to increased loads and decreased responsiveness during data collection.
Innovation Solution
An information collecting system with a two-level network structure, including an information network and a control network, utilizes mediation devices and units to manage data collection timing and load suppression, ensuring consistent information collection without affecting process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If attached information is collected during full-scale operation of the process control system, then information can be collected at any timing, but production efficiency is reduced and loads on the system increase
Solution Approach 1:
The system segments information collection into two distinct modes: real-time collection during operation and comprehensive collection during maintenance periods. The controller performs essential information gathering continuously, while the mediation device handles extensive information collection during maintenance when production efficiency is less critical, thus resolving the contradiction between timing flexibility and production efficiency.
Solution Approach 2:
The system implements periodic information collection cycles that alternate between real-time data gathering during operation and comprehensive information collection during maintenance periods. This periodic approach allows the system to maintain operational efficiency while periodically updating complete information sets, balancing timing flexibility with production requirements.
2Loss of time
If attached information is collected during full-scale operation, then information can be collected continuously, but consistency of information among devices cannot be ensured due to different collection timings
Solution Approach 1:
The mediation device implements a feedback mechanism that collects operation state information from each device and uses this feedback to coordinate information collection timing. When the mediation device determines that devices are in synchronized operational states, it triggers comprehensive information collection, ensuring consistency while maintaining operational continuity.
Solution Approach 2:
The system performs preliminary checks of device operation states before initiating comprehensive information collection. The mediation device预先 (in advance) verifies that devices are in appropriate states for consistent data collection, then coordinates the collection process to ensure information consistency across all devices while maintaining operational continuity.
3Reliability
If attached information is collected at specific timings (system introduction, extension, renovation, or periodic inspection), then process control is not influenced, but information collection timing is limited and cannot be performed at any timing
Solution Approach 1:
The system dynamically adjusts information collection strategies based on operational context. During normal operation, the controller performs minimal real-time information collection that does not disrupt process control stability. During maintenance periods, the mediation device performs comprehensive information collection. This dynamic approach allows information collection at any timing while preserving process control stability through adaptive collection intensity.
4Ease of operation
If a plurality of devices collect attached information independently during operation, then each device can maintain its own operation, but information inconsistency occurs when analyzing the entire process control system
Solution Approach 1:
The mediation device serves as an intermediary that coordinates information collection across multiple devices. Each device maintains operational independence by continuing to function normally, while the mediation device collects information from all devices in a coordinated manner, ensuring consistency across the entire process control system without disrupting individual device operations.
Data Source
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AI summary
An information collecting system collects information associated with (i) a controller connected to a control network and (ii) a host device connected to an information network located at a level higher than the control network, and includes a management device and an information collecting mediation device. The management device is connected to the information network, collects information associated with the host device, transmits an acquisition request for information associated with the controller to the information network, and manages the collected information associated with the host device and information associated with the controller. The information collecting mediation device is connected to the control network and the information network, collects information associated with the controller in consideration of capability information indicating a capability of at least one of the control network and the controller based on the acquisition request, and sends said collected information to the management device.