Plant Device Information Collection via Controller-Mediated Updates
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Solution Overview
Problem
Current methods for collecting configuration information in process control systems, such as those in petroleum refining and water treatment plants, are inefficient, often requiring direct device checks due to transmission failures, lack of position information, and network issues, leading to increased maintenance burdens and delayed responses to abnormalities.
Innovation Solution
An information collecting device that autonomously gathers engineering and device information from controllers and field devices, using a first and second collecting unit, and an update control unit to generate and update configuration information in a storage unit, allowing for centralized management without direct device inspection.
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 information due to network issues or device problems
Solution Approach 1:
The patent introduces a controller as an intermediary between field devices and the information collecting device. The controller collects configuration information from multiple field devices and transmits it to the information collecting device, thereby mediating the information transmission process. This resolves the contradiction by providing a reliable intermediate node that can aggregate and forward information even when direct device-to-collector communication fails due to network issues or device problems.
Solution Approach 2:
The controller performs preliminary collection of configuration information from field devices before transmitting it to the information collecting device. By pre-collecting and buffering information at the controller level, the system ensures that information is ready for transmission even when network conditions are poor or devices are temporarily unavailable, thus improving both efficiency and reliability.
2Measurement precision
If maintenance staff check devices directly to collect configuration information, then information accuracy is improved, but labor burden increases and response time decreases
Solution Approach 1:
The information collecting device autonomously collects configuration information from controllers and field devices without requiring maintenance staff to manually check each device. The system performs self-service information collection by automatically querying devices, aggregating data, and updating the information database, thereby eliminating manual labor while maintaining information accuracy through automated verification processes.
Solution Approach 2:
The patent replaces the manual mechanical process of maintenance staff physically checking devices with an automated electronic information collection system. The information collecting device uses communication protocols to automatically retrieve configuration information from devices, substituting human labor with automated electronic data gathering, thus improving ease of operation while maintaining accuracy.
3Ease of manufacture
If device list is created upon introducing or remodeling of system, then initial information setup is simplified, but information becomes outdated requiring frequent manual updates
Solution Approach 1:
The information collecting device continuously or periodically collects configuration information from controllers and field devices, maintaining up-to-date information without requiring manual updates. This continuous information gathering action replaces the periodic manual update process, ensuring the device list remains current while eliminating the time loss associated with frequent manual interventions.
Solution Approach 2:
The system performs preliminary creation of the device list during system introduction or remodeling, establishing the initial information structure. Subsequently, automated periodic updates maintain this list without requiring repeated manual setup actions, thus preserving the initial setup simplicity while eliminating ongoing update time loss.
Data Source
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 an arithmetic controller and an update controller. The arithmetic controller collects first information which is engineering information of the plant and 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 controller 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 based on a preset update cycle.