Process Control System Using TCP/IP Communication
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Solution Overview
Problem
Conventional process control systems for technical installations are inflexible, expensive, and require specialized hardware and software, limiting their installation distance and control options, with complex operation and high implementation costs due to their hierarchical structure and need for specific components.
Innovation Solution
A method using universal computers and software, employing the TCP/IP protocol for communication between field devices and a process control computer, allowing for flexible placement and operation over existing communication channels like the Internet or intranet, eliminating the need for specific bus systems and reducing hardware and software requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional process control systems use specialized hardware and software components tailored to particular tasks, then control functionality is achieved, but system complexity and implementation costs increase
Solution Approach 1:
The patent applies universality by using a single PC-based control system that can perform multiple functions previously requiring specialized components. The PC runs a database management system, process control software, and operator interface simultaneously, replacing the need for separate programmable controllers, supervisory control systems, and documentation systems. This multi-functional approach reduces system complexity while maintaining full control functionality.
Solution Approach 2:
The patent merges previously separate control system components into a unified PC-based system. The database management system, process control functions, operator interface, and documentation are combined into a single integrated system running on standard PC hardware, eliminating the need for multiple specialized systems and reducing overall complexity.
2Reliability
If conventional process control systems use specialized bus systems and wiring for connections, then communication reliability is maintained, but installation flexibility and distance limitations occur
Solution Approach 1:
The patent uses standard PC communication interfaces (serial ports, network interfaces) that can connect to various communication media including RS-232, RS-485, Ethernet, and wireless networks. This universal interface approach replaces specialized control system bus systems, providing both reliable communication and greater installation flexibility with no distance limitations.
3Extent of automation
If conventional process control systems use hierarchical structures with multiple levels, then control tasks are specialized, but system costs and operational complexity increase
Solution Approach 1:
The patent merges the field control level, process control level, and supervisory level into a single integrated PC-based system. The PC simultaneously handles real-time process control, data management, operator interfaces, and documentation functions that were previously distributed across multiple hierarchical levels, simplifying the structure while maintaining automation capabilities.
4Adaptability or versatility
If conventional process control systems require specific programming and compilation processes, then control software functionality is achieved, but implementation time and costs increase
Solution Approach 1:
The patent uses a database management system with pre-configured data structures, query languages, and reporting templates that are prepared in advance. This preliminary setup allows for rapid deployment of control functionality without requiring time-consuming programming and compilation processes, as the system can quickly adapt to different control tasks using pre-built components.
Data Source
AI summary
A method is disclosed for a system including at least one process management computer and a number of field devices, whereby status and control signals are transmitted between at least some of the field devices and the process management computer using a TCP/IP protocol over a communication channel, preferably a radio connection and/or the Internet. A process management system includes a process management computer with a web-server, a client computer with an Internet browser and a number of sensors and actuators. The process management system may preferably be operated by way of the Internet, using the client computer.