Process Image Backbone for Low-Latency Controller Data Access
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Solution Overview
Problem
Conventional automation systems lack a transparent mechanism for universal data access across different automation devices and layers, leading to reduced data resolution, increased latency, and underutilization of controller data analytics capabilities due to static logic and proprietary interfaces.
Innovation Solution
A process image backbone is introduced to unify data access from various automation devices, enabling decoupled interactions and providing uniform access to process image data across controllers, using a publish-subscribe messaging pattern and data registries to facilitate seamless data sharing and analytics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If data is pushed from controllers to upper level systems, then data access is provided, but data resolution is reduced and latency increases
Solution Approach 1:
The patent introduces a new dimension for data access by enabling horizontal data sharing between controllers at the same automation level through process image backbone instances, rather than only vertical data flow to upper levels. This allows controllers to directly access each other's process image data, maintaining full resolution and minimizing latency while still providing comprehensive data access.
2Ease of operation
If proprietary data access interfaces are used, then cross layer data access is facilitated, but universal data access across different devices is prevented
Solution Approach 1:
The patent implements a universal data access mechanism where each controller runs a process image backbone instance that can be accessed by any other controller in the system through standardized interfaces. This allows the same data access functionality to work across different device types and automation layers without requiring proprietary adapters, enabling universal data access while maintaining ease of operation through consistent interface patterns.
Solution Approach 2:
The process image backbone instance acts as an intermediary layer between controllers, providing a standardized access mechanism that translates diverse controller data into a uniform format. This intermediary enables universal data access across different devices without requiring direct proprietary interfaces between each controller pair, resolving the contradiction between ease of access and versatility.
3Stability of the object's composition
If static controller logic is used, then control stability is maintained, but dynamic adaptive changes and post commissioning modifications are prevented
Solution Approach 1:
The patent enables dynamic controller logic by allowing controllers to access process image data from other controllers and adapt their control behavior in real-time based on this data. The system supports runtime modifications and post-commissioning changes while maintaining stability through the structured process image backbone interface, which provides a stable framework for data access while allowing flexible control logic adaptations.
Data Source
AI summary
A system for providing access to locally stored process image data to other devices in an industrial production environment includes a plurality of controller devices and a process image backbone. Each respective controller device comprises the following: a volatile computer-readable storage medium comprising a process image area; a non-volatile computer-readable storage medium; a control program configured to provide operating instructions to a production unit; an input/output component configured to update the process image area during each scan cycle or upon the occurrence of one or more events with process image data items associated with the production unit; and a historian component configured to locally store the process image data items of the process image area as time series data in the non-volatile computer-readable storage medium. The process image backbone provides the plurality of controllers with uniform access to the process image data items of each programmable logic device.