Remote Control Twin for Industrial Configuration Validation
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Solution Overview
Problem
Industrial process control systems face challenges in validating control configurations for equipment from multiple manufacturers, which is costly and time-consuming, requiring on-site testing and potential repeated validation procedures.
Innovation Solution
Implementing a remote control system that acts as a 'twin' of a local control system, allowing for remote interfacing and validation of process equipment through a network, using protocols like PROFINET or ETHERNET/IP, and enabling control configurations to be validated at the OEM's facility before site installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If on-site testing and validation is performed for control configurations, then regulatory requirements are satisfied and system reliability is ensured, but time consumption and costs increase significantly
Solution Approach 1:
The patent applies preliminary action by performing control configuration validation at the OEM's facility before equipment installation at the customer site. The local control system validates control configurations in advance using process equipment at the OEM facility, so that when equipment is installed at the customer site, validation has already been completed. This eliminates the need for repeated on-site validation testing, significantly reducing validation time while maintaining regulatory compliance and system reliability.
2Reliability
If on-site testing and validation is performed for control configurations, then regulatory requirements are satisfied, but costs increase significantly
Solution Approach 1:
The patent performs control configuration validation at the OEM's facility before equipment shipment, eliminating the need for costly on-site validation testing at customer facilities. By completing validation in advance using available process equipment at the OEM facility, the system avoids repeated testing costs while ensuring regulatory compliance is met.
3Reliability
If control configurations are validated after equipment installation, then system reliability is ensured, but productivity is reduced due to repeated validation procedures
Solution Approach 1:
The patent performs control configuration validation before equipment installation at the customer site. The local control system validates control configurations using process equipment at the OEM facility in advance, so that when equipment is installed at the customer site, validation has already been completed. This eliminates repeated validation procedures and accelerates the installation process, improving productivity while maintaining system reliability.
4Ease of operation
If a remote control system acts as a twin of a local control system, then ease of operation is improved for remote engineering, but device complexity increases
Solution Approach 1:
The patent creates a remote control system that is a twin or copy of the local control system. The remote control system replicates the functionality and interface of the local control system, allowing operators to remotely configure, monitor, and control process equipment without being physically present at the customer site. This copying approach simplifies remote operation while the underlying complexity is managed through software-based control logic.
Solution Approach 2:
The remote control system acts as an intermediary between the operator and the local control system. It provides a remote interface that mediates control operations, allowing operators to interact with the local control system over a network connection. This intermediary layer simplifies the user experience by providing familiar control interfaces while managing the complexity of remote communication and control logic execution.
Data Source
AI summary
A method in an industrial process control and remote engineering system comprises receiving, by a remote control system, a control configuration, interfacing, by the remote control system, via a network, with at least one process equipment, and remotely controlling, by the remote control system, the at least one process equipment according to the control configuration. In some embodiments of the method, the remote control system is a twin of a local control system.