Plant Configuration Data Collection via Engineering and Device Mapping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for collecting configuration information in process control systems are inefficient, as they often require direct device checks, may fail due to non-transmitting devices, lack position information, or are hindered by network issues, leading to increased maintenance burdens and delayed response times when abnormalities occur.
Innovation Solution
An information collecting device that includes a first unit for collecting engineering information, a second unit for collecting device information from controllers and field devices, and an update control unit that generates and updates configuration information based on preset definitions, allowing for automated storage without direct device checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If configuration information is collected automatically from field devices, then collection efficiency is improved, but reliability deteriorates because devices may not transmit configuration information due to operating states or network problems
Solution Approach 1:
The patent introduces a configuration information management device as an intermediary between field devices and the control system. This mediator collects configuration information from devices through the network and manages it centrally, allowing automatic collection while handling transmission failures and device unavailability through centralized management and retry mechanisms.
Solution Approach 2:
The system performs preliminary actions by establishing device lists with position information and connection details before actual configuration collection. This preparatory work ensures that even if automatic collection fails, the maintenance staff can locate and access devices using pre-collected position information, reducing the impact of transmission failures.
2Loss of information
If device lists are used to collect configuration information, then position information is preserved for maintenance, but ease of operation deteriorates due to the need to manually check each device
Solution Approach 1:
The configuration information management device automatically collects configuration information from field devices and updates the device list without requiring manual intervention. The system serves itself by performing automatic information collection, synthesis, and storage, eliminating the need for maintenance staff to manually check each device while preserving position information in the updated device list.
Solution Approach 2:
The system performs preliminary information collection and synthesis before maintenance operations are needed. By automatically gathering and storing configuration information with position data in advance, the system ensures both position information retention and operational simplicity when maintenance staff need to access device details.
3Measurement precision
If direct device checks are performed for configuration collection, then information accuracy is improved, but loss of time increases due to manual verification requirements
Solution Approach 1:
The patent replaces manual mechanical checking of devices with automated electronic information collection through the network. The configuration information management device electronically gathers configuration data from field devices, substituting manual verification with automated digital collection, thereby maintaining information accuracy while dramatically reducing collection time.
Solution Approach 2:
The system creates copies of configuration information from field devices and stores them centrally in the configuration information management device. This copying process allows accurate configuration data to be obtained without requiring maintenance staff to physically access and verify each device, reducing time loss while preserving information accuracy.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An information collecting device controls a plant based on process data acquired from controllers and field devices connected to the controllers. The information collecting device includes a first collecting unit, a second collecting unit and an update control unit. The first collecting unit collects first information which is engineering information of the plant. The second collecting unit collects second information which is device information from a controller, a field device or a combination of both selected from the controllers and the field devices. The update control unit generates third information based on a definition in which the first information and the second information are set in advance, and updates the third information in a storage unit based on a preset update cycle.