Shadow Manager for Automatic Control Object Discovery
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Solution Overview
Problem
Current process control systems require pre-configuration and detailed knowledge of control objects to implement shadowing, making it cumbersome to introduce changes or new objects, and often necessitate taking shadowing devices offline for reconfiguration.
Innovation Solution
The implementation of a shadowing device with a shadow manager and shadow library that automatically discovers and configures shadowed control objects without prior knowledge, allowing for real-time adaptation and data mirroring in process control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-configuration and detailed knowledge of control objects are required to implement shadowing, then shadowing can be implemented with stable and reliable configuration, but the system becomes cumbersome to modify and requires offline reconfiguration
Solution Approach 1:
The shadow manager performs preliminary actions by automatically discovering control objects and their configurations before shadowing operations begin. The system proactively queries the control system for control object definitions, data types, and relationships, storing this information in advance so that shadowing can commence immediately without manual pre-configuration, thus resolving the contradiction between reliability and adaptability.
2Manufacturing precision
If manual configuration of shadowing devices is required, then configuration accuracy can be ensured, but productivity decreases and offline reconfiguration is necessary
Solution Approach 1:
The shadow manager implements self-service by automatically querying the control system for control object configurations, data types, and relationships without human intervention. It autonomously discovers control objects, retrieves their definitions, and configures the shadowing device accordingly, ensuring both configuration accuracy through direct source retrieval and high productivity through automation, eliminating the need for manual configuration.
3Stability of the object's composition
If shadowing devices must be taken offline for reconfiguration, then configuration integrity can be maintained, but system availability and operational continuity are reduced
Solution Approach 1:
The system enables continuity of useful action by allowing the shadow manager to discover and configure control objects dynamically while the shadowing device remains online and operational. The shadow manager continuously monitors for changes in control object configurations and updates the shadowing device in real-time without requiring offline reconfiguration, thus maintaining both configuration integrity and system availability simultaneously.
4Measurement precision
If detailed knowledge of control objects is required beforehand, then shadowing precision can be achieved, but device complexity and ease of operation are worsened
Solution Approach 1:
The shadow manager acts as an intermediary between the control system and the shadowing device. It queries the control system for control object definitions, data types, and relationships, processes this information, and automatically configures the shadowing device accordingly. This intermediary approach ensures shadowing precision by obtaining accurate control object information while hiding the complexity from the user, as the shadow manager handles all configuration details automatically.
5Reliability
If manual configuration steps are required, then configuration control can be maintained, but ease of operation and time consumption are negatively impacted
Solution Approach 1:
The shadow manager implements feedback by continuously monitoring the control system for control object configurations and changes, and automatically adjusting the shadowing device configuration in response. This feedback mechanism maintains configuration control through continuous verification against the control system while dramatically improving ease of operation, as users simply need to initiate the shadowing process and the system handles all configuration steps automatically based on real-time feedback from the control system.
Data Source
AI summary
Generic shadowing allows a shadowing device in a process plant to automatically discover, without pre-configuration or pre-definition, and without the use of a configuration tool, source control objects that are hosted at other devices and that are to be shadowed. Source control objects may utilize any data type, format, structure, language, etc. The shadowing device includes a shadow manager and a set of primitive components defining simple data types that are utilized to discover the configurations/definitions and data types of source control objects, and includes a shadow library in which signatures of discovered source control objects are stored. Signatures are instantiated and used by the shadowing device to provide dynamic data to recipient devices, applications, and/or control objects in the process control system, where the dynamic data is a mirror of data that is observed first-hand by the source control objects during their on-line operations at their host devices.