Process Control Data Collection via Field Device Integration
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Solution Overview
Problem
Process control systems face challenges in data collection due to varying data volume capacities and requirements across different communication protocols, leading to data latency and reduced control performance, especially in systems using multiple networks, buses, and protocols.
Innovation Solution
The method involves using electronic device descriptions (EDDs) to determine data sampling rates and transmission methods, enabling access to data with different properties and requirements, and employing a Field Device Integration (FDI) standard to facilitate communication across diverse protocols, allowing for more complex and data-intensive field devices to operate on lower-capacity communication busses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data is collected and transmitted using traditional communication protocols, then the system can operate with existing infrastructure, but data latency increases and control performance degrades
Solution Approach 1:
The system performs preliminary actions by collecting and buffering process control data locally at the field device before transmission is needed. The data is staged in a buffer memory and prepared for transfer in advance, allowing the communication protocol to retrieve and transmit data without causing latency when the data is actually needed for control decisions.
Solution Approach 2:
The patent introduces an intermediary data collection and buffering mechanism between the field device sensor and the control system. This intermediary buffer acts as a mediator that decouples the data collection rate from the transmission rate, allowing efficient data handling without compromising control loop responsiveness.
2Measurement precision
If advanced field devices with high data volume requirements are used, then measurement precision and data quality improve, but compatibility with lower-capacity communication protocols deteriorates
Solution Approach 1:
The patent segments the data transmission process into separate stages: data collection at the field device, local buffering, and on-demand retrieval by the communication protocol. This segmentation allows advanced field devices to collect high-quality data while the communication protocol only needs to handle data retrieval and transmission, not the entire data pipeline.
Solution Approach 2:
The buffer memory serves multiple functions: it acts as a data collection point for advanced field devices, a staging area for data preparation, and a source for on-demand retrieval by various communication protocols. This multi-functionality enables the system to support both high-data-volume devices and lower-capacity protocols simultaneously.
3Speed
If data is transmitted continuously at high rates, then real-time control performance improves, but communication bandwidth requirements and system complexity increase
Solution Approach 1:
Instead of continuous high-rate transmission, the system uses periodic action where the communication protocol retrieves and transmits data at specific intervals or events. The field device collects data continuously at high rate, but transmission occurs periodically when the buffer is ready or when control decisions are needed, reducing overall communication bandwidth requirements.
Data Source
AI summary
Methods, apparatus, and articles of manufacture to collect process control data are disclosed. An example method to collect process control data includes registering an electronic device description describing a parameter to be measured and a measurement sampling rate, measuring the parameter based on the measurement sampling rate, storing data representative of the measured parameter in a data structure, and transferring data in the data structure to a first process control device via a process control network in response to at least one of a request for the data, a condition associated with the data, or an event associated with the data.