Message Broker for Industrial Data Exchange
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Solution Overview
Problem
Conventional industrial control systems lack the ability to seamlessly exchange data between disparate components, leading to issues like failed communications, delayed responses, and data management complexities, which hinder real-time optimization and compliance in modern manufacturing environments.
Innovation Solution
A historian with a correlation component that employs heuristic and implicit correlation models to infer relationships between disparate data events and industrial processes, enabling predictive analytics and corrective actions, thereby improving data exchange speed and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control systems architectures are used for data exchange between controllers and business systems, then system compatibility is maintained, but data exchange efficiency deteriorates due to protocol mapping complexities and communication failures
Solution Approach 1:
The patent introduces a message broker as an intermediary component that receives messages from multiple controllers using different protocols and distributes them to appropriate business systems. The message broker handles protocol translation and message routing centrally, eliminating the need for complex point-to-point protocol mappings between each controller and business system, thereby improving data exchange reliability while reducing overall system complexity
Solution Approach 2:
The message broker serves multiple functions including receiving messages from various controllers, translating between different protocols, routing messages to appropriate destinations, and providing message storage and retrieval capabilities. This multi-functional approach consolidates what would otherwise require multiple separate components, reducing device complexity while maintaining reliable data exchange
2Productivity
If real-time data collection from multiple global manufacturing sites is implemented, then productivity optimization is enabled, but communication delays and data loss increase due to network overhead
Solution Approach 1:
The message broker pre-processes and queues messages before they need to be delivered to business systems. By maintaining a message queue and preparing messages in advance, the system can handle network variations and delays without losing data or compromising real-time processing requirements, thus enabling productivity optimization while minimizing communication delays
Solution Approach 2:
The system implements acknowledgment mechanisms where business systems confirm receipt of messages to the message broker. This feedback loop ensures that critical messages are delivered reliably even in the presence of network delays, allowing the system to maintain real-time data collection from multiple sites without significant data loss or time penalty
3Reliability
If local recording modules are added to controllers for data archiving, then compliance requirements are met, but controller processing overhead increases due to additional storage and management functions
Solution Approach 1:
The patent extracts the data archiving and recording functions from the controllers themselves and places them in dedicated servers or centralized storage systems. Controllers only need to send data to the message broker for archiving, removing the burden of local storage management from the controllers. This reduces controller processing energy consumption while maintaining compliance through centralized archiving capabilities
Solution Approach 2:
The message broker acts as an intermediary that handles data archiving requests from controllers and manages storage operations. By delegating archiving responsibilities to the message broker and dedicated storage systems, controllers are freed from the energy-intensive tasks of local data management while compliance requirements are still met through systematic archiving
4Adaptability or versatility
If custom glue code is written to integrate systems with different protocols and formats, then system interoperability is achieved, but configuration and management difficulty increase
Solution Approach 1:
The message broker provides universal support for multiple communication protocols and data formats through a single platform. Instead of writing custom glue code for each protocol combination, the message broker handles protocol translation and message formatting centrally, achieving system interoperability while dramatically simplifying configuration and management through a unified interface
Data Source
AI summary
Systems and methods that discover relations and correlates among disparate pieces of data, to infer possible relationships between the industrial process and historian data/events to improve industrial operations. A correlation component can employ heuristic models to capture process data/event data, and can further include an implicit correlation component and an explicit correlation component. Accordingly, relations among various parameters can be discovered (e.g., dynamically) and proper corrective adjustments supplied to the industrial process.