Process Control Decoupling with Signal Objects and Shadow Blocks
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Solution Overview
Problem
Existing process control systems require extensive configuration to accommodate different field devices and communication protocols, leading to complexity and inefficiency, especially when changes occur in the process control network.
Innovation Solution
The implementation of intermediary components such as signal objects and shadow blocks to decouple process control logic operations from communication operations within the process control network, allowing for architecture-independent process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If process control systems are configured to accommodate different field devices and communication protocols, then the system can support diverse devices, but the configuration complexity increases significantly
Solution Approach 1:
The patent introduces intermediary components (signal objects, shadow blocks, communication modules) that act as mediators between the process control logic and the physical field devices. These intermediaries handle protocol-specific communication details, allowing the control logic to remain architecture-independent while supporting diverse devices through standardized interfaces.
Solution Approach 2:
The system is segmented into distinct functional layers: process control logic layer, communication abstraction layer (with signal objects and shadow blocks), and physical device layer. This segmentation allows each layer to be developed and configured independently, reducing overall system complexity while maintaining versatility.
2Adaptability or versatility
If the process control network architecture changes, then the system can adapt to new technologies, but extensive reconfiguration of control logic is required
Solution Approach 1:
Communication modules serve as intermediaries that encapsulate architecture-specific details. When the network architecture changes, only the communication modules need to be updated, while the process control logic remains unchanged, significantly reducing reconfiguration time.
Solution Approach 2:
Shadow blocks create virtual copies of field device behavior within the controller memory. These shadow blocks allow the control logic to interact with standardized representations of devices rather than architecture-specific implementations, enabling rapid adaptation to architectural changes.
3Extent of automation
If control logic is directly coupled to communication operations, then integration is tight, but the system becomes dependent on specific communication architectures
Solution Approach 1:
The system segments control operations into architecture-independent process control logic and architecture-specific communication operations. Signal objects and shadow blocks serve as the segmentation interface, allowing automated control while maintaining independence from specific communication architectures.
Solution Approach 2:
Signal objects act as intermediaries that bridge the process control logic and communication operations. They provide automated data exchange while decoupling the control logic from communication architecture dependencies, achieving both high integration and architectural independence.
Data Source
AI summary
Process control systems for operating process plants are disclosed herein. The process control systems include control modules that are decoupled from the I/O architecture of the process plants using signal objects or generic shadow blocks. This decoupling is effected by using the signal objects or generic shadow blocks to manage at least part of the communication between the control modules and the field devices. Signal objects may convert between protocols used by control modules and field devices, thus decoupling the control modules from the I/O architecture. Generic shadow blocks may be automatically configured to mimic the operation of field devices within a controller executing the control modules, thus partially decoupling the control modules from the I/O architecture by using the shadow blocks to manage communication between the control modules and the field devices.