Plant I/O Auxiliary Control for Cooperation Failure Continuity
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Solution Overview
Problem
In plant control systems where input/output and control functions are separated, stable operation is challenging due to potential impairments in cooperation between these functions, leading to increased risk of disconnection and maintenance-related disruptions, which can result in significant opportunity losses and operational instability.
Innovation Solution
A plant control system comprising a controller and an input/output device that operate in cooperation, with the controller generating first output data and the input/output device having an auxiliary control unit to generate second output data, an input/output unit for relaying communication, and a management unit that controls data transmission to ensure continuity of operation even when cooperation is impaired.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the input/output function and control function are allocated to different devices, then the control function capacity can be easily increased and maintenance ability is improved, but the cooperation between input/output function and control function may be impaired leading to unstable plant operation
Solution Approach 1:
The system performs preliminary actions by having the I/O device calculate auxiliary control values in advance and store them, so that when the controller becomes unavailable, the I/O device can immediately use these pre-calculated values to maintain control without interruption, thus preventing cooperation impairment from affecting plant operation stability
Solution Approach 2:
The management device acts as an intermediary that monitors the cooperation status between the controller and I/O device, detects when cooperation is impaired, and triggers the switch to auxiliary control mode, thereby mediating the transition and maintaining system reliability despite the separation of functions
2Ease of operation
If the physical distance between input/output function and control function is increased, then installation flexibility is improved, but the path is more likely to be disconnected
Solution Approach 1:
The I/O device is equipped with preliminary calculation capabilities to compute auxiliary control values in advance, so that even when physically separated from the controller, it can independently maintain control functions without requiring continuous communication, thus compensating for connection instability caused by increased physical distance
Solution Approach 2:
The I/O device performs self-service by autonomously calculating and outputting control values when the controller is unavailable, enabling it to function independently without relying on the controller, thus maintaining system operation despite physical separation and potential connection issues
3Reliability
If maintenance frequency of controller is increased, then system reliability is improved, but operation of each device is temporarily stopped leading to loss of cooperation
Solution Approach 1:
The I/O device calculates and stores auxiliary control values in advance before maintenance is needed, so that when the controller is taken offline for maintenance, the I/O device can immediately take over control functions using these pre-calculated values, thus avoiding operation stoppage and maintaining continuous plant operation
Solution Approach 2:
The system ensures continuity of useful action by enabling the I/O device to maintain control function output during controller maintenance periods, preventing interruption of plant operation and eliminating the loss of cooperation that would normally occur during maintenance stoppages
Data Source
AI summary
A controller includes a main control unit that generates first output data for controlling an operation instrument based on reception data that is received from a measuring instrument. An IO device includes an auxiliary control unit that generates second output data for controlling the operation instrument based on the reception data received from the measuring instrument, an input/output unit that relays communication between both the main control unit and the auxiliary control unit and both the measuring instrument and the operation instrument, and a management unit that controls the input/output unit such that, when the cooperation has been impaired, the second output data generated by the auxiliary control unit is transmitted to the operation instrument.