Process Controller Auto-Configuration for Docked Mobile Equipment
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Solution Overview
Problem
Conventional process control systems in industrial processing facilities require manual and tedious steps for connecting and disconnecting mobile equipment (ME) to establish communication connections, limiting productivity and leading to potential unwanted alarms when ME is disconnected.
Innovation Solution
A process controller with a computing device and memory that dynamically and automatically reconfigures to connect multiple instances of ME using a single configuration instance, allowing simultaneous connection of multiple MEs of the same class, utilizing RFID or other address reading mechanisms to set IP addresses and enable communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual connection and disconnection steps are used to establish communication between ME and process controller, then communication connection is established, but productivity is limited and unwanted alarms occur
Solution Approach 1:
The system performs self-identification and self-configuration automatically. The ME reads its own identification (e.g., via RFID tag) and the process controller automatically configures the communication parameters including IP address assignment, eliminating the need for manual operator intervention in the connection establishment process
Solution Approach 2:
The ME pre-configures its identification information (such as RFID tag data) before connection. When connected to the process controller, this pre-stored identification is automatically read and used for immediate configuration, enabling rapid connection without manual setup steps
2Adaptability or versatility
If single configuration instance is used for ME connection, then configuration simplicity is maintained, but multiple MEs of the same class cannot be connected simultaneously
Solution Approach 1:
The system dynamically changes the IP address parameter based on the ME's identification. A single configuration instance template is used, and the specific IP address parameter is automatically adjusted during connection based on the read identification, allowing multiple MEs to connect simultaneously without creating multiple configuration instances
Solution Approach 2:
The system uses a single configuration instance template that can be conceptually copied or instantiated multiple times through parameter substitution. The same configuration structure serves multiple MEs by dynamically assigning different IP addresses based on their individual identifications, avoiding the need to manually create separate configuration instances for each ME
3Ease of operation
If ME is disconnected manually, then communication connection is terminated, but nuisance alarms are generated
Solution Approach 1:
The system continuously monitors the connection status and automatically manages the configuration based on whether ME is connected or disconnected. When ME disconnects, the system receives feedback about the disconnection and automatically handles the configuration cleanup, preventing nuisance alarms from being generated due to stale configuration data
Data Source
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AI summary
A method (100) of dynamically establishing a communication connection for mobile equipment (ME) (430) to a process controller (440) of an industrial processing facility (IPF) (200) configured to run an industrial process. The process controller has a computing device includes a processor (208a) with a memory (208b) storing a different ME classes including a first ME class that the ME is in. The computing device is configured to implement dynamic establishment of a communication connection for ME to the process controller, including reading (102) a representation of a first industrial protocol for the ME while docked at the process controller, translating (103) the representation into a first industrial protocol address, and setting (104) the first industrial protocol address as a first configuration instance in its industrial protocol infrastructure block to render the ME an attached ME. After undocking (105) the ME, the process controller communicates with the ME while controlling the industrial process.