PID Asset Categorization Across Enterprise Control Layers

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Solution Overview

Problem

Existing process control and automation systems face challenges in efficiently monitoring and categorizing large numbers of PID assets across multiple hierarchical layers, leading to inefficiencies and potential malfunctions that affect overall performance of advanced control systems.

Innovation Solution

A computer-implemented method and apparatus for categorizing PID controller performance using performance analysis models, generating diagnostic data, and automatically adjusting parameters to improve asset performance and efficiency by categorizing PID assets into multiple categories across a multi-layered enterprise system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If multiple hierarchical layers with large numbers of PID assets are monitored using traditional methods, then comprehensive monitoring coverage is achieved, but monitoring efficiency and operational performance deteriorate

Engineering Contradiction:

Improvenumber of PID assets monitoredVSAvoidmonitoring efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent segments the large number of PID assets into multiple hierarchical layers (regulatory layer with PID controllers, advanced process control layer with APC controllers, and plantwide optimizer layer with PWO controllers). This segmentation allows for organized monitoring at different levels, improving overall monitoring efficiency while maintaining comprehensive coverage of all assets.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If traditional monitoring methods are used for PID assets, then system simplicity is maintained, but detection precision and performance diagnosis capability deteriorate

Engineering Contradiction:

Improvemonitoring system complexityVSAvoidperformance diagnosis precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent introduces performance diagnosis rules as intermediary elements that mediate between raw KPI data and performance assessments. These rules serve as a structured intermediary layer that enhances diagnosis precision by systematically evaluating KPI data against predefined performance criteria, without requiring complex custom analysis for each asset.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent utilizes multiple performance parameters (KPIs such as compression factor, oscillation index, service factor, etc.) to assess PID asset performance. By monitoring and analyzing changes in these parameters against threshold values defined in performance diagnosis rules, the system achieves precise performance detection while maintaining a manageable monitoring framework.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If manual monitoring and categorization of PID assets is performed, then system complexity is reduced, but time consumption and operational efficiency worsen

Engineering Contradiction:

Improvesystem complexityVSAvoidtime for performance assessment

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The system implements self-service through automated performance diagnosis and categorization. Performance analysis models automatically evaluate KPI data against performance diagnosis rules to generate performance diagnostic data and issue classifications without manual intervention. The system also automatically determines improvement actions and initiates prediction-based operations, eliminating time-consuming manual monitoring while maintaining system simplicity.

Inventive Principle:

Principle #25Self-service

4Loss of information

If comprehensive performance analysis is conducted on all PID assets, then performance insight quality is improved, but computational resources and processing time worsen

Engineering Contradiction:

Improveperformance information qualityVSAvoidcomputational resource consumption

Core Design Contradiction:

Loss of informationVSUse of energy by moving object

Solution Approach 1:

The patent applies partial action by focusing performance analysis on specific performance indicators and issue classifications that are most critical for operational decision-making. Rather than analyzing all possible parameters equally, the system selectively evaluates KPIs against performance diagnosis rules to generate actionable insights, reducing computational overhead while maintaining high information quality for key performance aspects.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20260037903A1Systems, apparatuses, methods, and computer program products for categorizing PID asset performance in a multi-layered enterprise system

Publication Date: 2026.02.05 HONEYWELL INTERNATIONAL INC

AI summary

Embodiments of the present disclosure relate to categorizing PID controllers. Performance diagnostic data for a PID controller may be generated by applying KPI data for the PID controller to one or more performance diagnosis rules. Performance issue classification for the PID controller may be generated based on the performance diagnostic data. Performance rating classification for the PID controller may be generated based on performance rating data for the PID controller. An improvement action for the PID controller may be generated based on the performance issue classification and the performance rating classification for the PID controller. Performance of one or more prediction-based actions may be initiated based on the improvement action.