Open-Socket Interface for High-Speed Industrial Data Acquisition
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Solution Overview
Problem
Current industrial control systems face limitations in data transmission rates, often resulting in slow response times due to low data transmission rates from programmable controllers to remote clients, which are insufficient for real-time control and monitoring in complex industrial applications, and are often incompatible with standard operating systems or third-party applications.
Innovation Solution
A system comprising a first processor generating data arrays, a second processor converting these arrays into messages with time stamps and tags, and an open-socket interface transmitting these messages as packets to a client application, which buffers and converts them into a standard structured data format, enabling high-speed data transmission rates of less than 20 milliseconds for up to 1000 data points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If data transmission is performed using conventional industrial control systems, then data can be transmitted from programmable controllers to remote clients, but the transmission rate is limited to 150-500 milliseconds which is too slow for real-time control applications
Solution Approach 1:
The system segments data into discrete data arrays that are processed and transmitted individually. Each data array contains specific process data that is handled separately through the conversion and transmission pipeline, enabling efficient batch processing and reducing overall transmission time.
Solution Approach 2:
A data converter acts as an intermediary component between the programmable controller and the client application. This converter receives data arrays from the controller, converts them into the appropriate format, and transmits them to the client, thereby enabling high-speed communication while maintaining compatibility with standard systems.
2Adaptability or versatility
If proprietary operating systems are used in industrial control systems, then control functionality can be maintained, but compatibility with standard operating systems and third-party applications is lost
Solution Approach 1:
The data converter is designed to perform multiple functions: it receives data from programmable controllers, converts data arrays into appropriate formats, transmits data to client applications, and ensures compatibility with standard operating systems. This multi-functional component enables the system to work across different platforms without requiring proprietary operating systems.
Solution Approach 2:
The converter serves as an intermediary layer that translates between the controller's data format and standard system formats, enabling compatibility with third-party applications and standard operating systems while maintaining the controller's original functionality.
Data Source
AI summary
A high speed industrial control system and data acquisition system and method are disclosed that enable high speed data transmission rates from an control system to a remote client application. In one embodiment, the system includes a first processor, a second processor, an open-socket interface, and a client application. The first processor is configured to generate data arrays and the second processor is configured to receive and convert the arrays into time stamped message sets. The open-socket interface may be coupled to the second processor and may be configured to transmit packet sets from the second processor to a client application. The client application may be configured to convert each packet set into individual records that are included in a standard structured data format. One of the standard structured data format may be a standard database format.