Plant Control Locking Mechanism for Online Definition Updates

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In plant control systems, changing definitions in subsystem communication input-output modules without stopping the plant is challenging due to the large amount of data involved, leading to potential errors and discontinuity in data updates.

Innovation Solution

A plant control system that includes an engineering apparatus for defining changes and a control apparatus with a locking mechanism to inhibit output value settings, combined with tracking communication to ensure data continuity during online definition changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If definition information is changed online without stopping the plant, then productivity is improved, but data continuity and reliability deteriorate due to large data volume and potential errors

Engineering Contradiction:

Improveonline definition change capabilityVSAvoiddata continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The locking part is activated before the definition information is changed to preliminarily prevent any output value settings. This preliminary action ensures that no data updates occur during the definition change process, thereby maintaining data continuity and reliability while allowing online definition changes to proceed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The locking part acts as an intermediary mechanism between the definition change process and the output value setting process. It mediates by temporarily blocking output value settings during definition changes, preventing data inconsistency while allowing the definition change to complete, thus ensuring both productivity and reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of time

If definition information is changed online, then loss of time is reduced, but manufacturing precision deteriorates due to potential errors in data updates

Engineering Contradiction:

Improveplant stop timeVSAvoiddata update accuracy

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The locking part applies preliminary anti-action by preventing output value settings before errors can occur during online definition changes. This proactive blocking mechanism eliminates the risk of data update errors while allowing the definition change to proceed without stopping the plant, thus maintaining both time efficiency and data accuracy.

Inventive Principle:

Principle #9Preliminary anti-action

3Reliability

If the locking mechanism is implemented, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvedata integrity during definition changeVSAvoidcontrol system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking function is extracted as a separate, dedicated component (locking part) from the complex definition change process. This extraction simplifies the overall system architecture by isolating the reliability-critical function into a discrete element that can be independently controlled and managed, reducing the complexity of coordinating multiple functions during definition changes.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS8280530B2Plant control system

Publication Date: 2012.10.02 YOKOGAWA ELECTRIC CORP

AI summary

A plant control system includes: an engineering apparatus for defining change information so as to change definition information about the system; and a control apparatus for referring to the change information downloaded from the engineering apparatus to set an output value of a field device. The control apparatus includes a locking part for inhibiting setting of the output value of the field device.