PLC Virtual Modules for Process Instrument Anomaly Detection
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Solution Overview
Problem
Process instruments lack effective anomaly diagnosis capabilities for issues like pressure sensor pulse line blockage and measurement errors caused by gas entrainment, which affect measurement accuracy and subsequent analysis, especially in low-power or low-cost industrial control systems.
Innovation Solution
Integrating virtual function modules on a programmable logic controller (PLC) with mappings to anomaly diagnosis algorithms on a service provision system, allowing for anomaly detection and using preset default data to correct inaccurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data-intensive anomaly diagnosis algorithms are used to diagnose process instrument anomalies, then measurement accuracy and diagnostic capability are improved, but system resource consumption and computational load increase
Solution Approach 1:
The patent extracts the computationally intensive anomaly diagnosis algorithms from the PLC and places them on an external server system. The PLC retains only lightweight virtual function modules that communicate with the server, significantly reducing the computational burden and resource consumption on the PLC while maintaining access to sophisticated diagnostic capabilities.
Solution Approach 2:
The patent introduces virtual function modules as intermediaries between the PLC and the external anomaly diagnosis algorithms. These virtual modules serve as a communication bridge, allowing the PLC to access sophisticated diagnostic algorithms on the server without directly executing them, thus maintaining measurement accuracy while minimizing local resource consumption.
2Reliability
If sophisticated anomaly diagnosis algorithms are integrated into the PLC, then diagnostic capability for process instruments is improved, but device complexity and implementation difficulty increase
Solution Approach 1:
The patent segments the anomaly diagnosis system into two distinct parts: lightweight virtual function modules residing in the PLC and sophisticated diagnosis algorithms residing on an external server. This segmentation allows the PLC to maintain simplicity while the server handles the complex computational tasks, resolving the contradiction between diagnostic capability and device complexity.
Solution Approach 2:
The patent creates universal virtual function modules that can interface with multiple different anomaly diagnosis algorithms on the server. These virtual modules provide a standardized interface that works with various diagnostic algorithms, reducing the complexity of integrating different diagnostic capabilities into the PLC system.
3Device complexity
If process instruments use basic self-diagnostic abilities only, then device simplicity is maintained, but diagnostic coverage and anomaly detection capability are limited
Solution Approach 1:
The patent merges the basic self-diagnostic capabilities of process instruments with sophisticated anomaly diagnosis algorithms through the virtual function module interface. This combination allows instruments to maintain their simplicity while gaining access to enhanced diagnostic coverage through the integrated server-based algorithms.
Data Source
AI summary
An anomaly detection method and system for a process instrument, and a storage medium are disclosed. The method includes that: a programmable logic controller (PLC) receives measurement data of a process instrument, the measurement data being periodically stored into a historical database so that a service providing system can perform reading and evaluation. At least one virtual function module is integrated on the PLC, a mapping relation is formed between at least one input channel of each virtual function module and output of at least one anomaly diagnosis algorithm disposed on the service providing system, and each anomaly diagnosis algorithm is used for diagnosing whether an anomaly exists in the process instrument. When an anomaly indication outputted by the service providing system is received via an input channel of the virtual function module, the PLC determines that an anomaly exists in the corresponding process instrument.