State Machine Function Block with Graphical Configuration Database

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Solution Overview

Problem

Current methods for tracking the status of systems in process plants, such as process control and safety systems, are tedious, time-consuming, and prone to errors, especially when using programming languages or sequential function charts, which can lead to serious safety issues in industrial settings.

Innovation Solution

The implementation of a state machine function block that can be easily integrated into a function block diagram programming environment, allowing configuration through a graphical user interface, with a matrix or diagram-based mechanism to specify state transitions and outputs, reducing the complexity of configuring and documenting the operation of state machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If programming languages or sequential function charts are used to track system status, then the system can implement complex control logic, but the configuration process becomes tedious, time-consuming, and error-prone

Engineering Contradiction:

Improvecontrol logic capabilityVSAvoidconfiguration ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent uses a graphical user interface that displays a visual representation (copy) of the state machine configuration, allowing operators to configure state transitions through graphical elements rather than writing programming code or complex sequential function charts. This visual copying approach maintains full control logic capability while dramatically simplifying the configuration process and reducing errors.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical process of writing and debugging programming code with an automated graphical interface system. The GUI automatically processes graphical configuration inputs and generates the corresponding control logic, substituting manual coding mechanics with an automated visual configuration system that is both more versatile and easier to operate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If programming languages or sequential function charts are used to track system status, then the system can implement complex control logic, but the configuration time increases significantly

Engineering Contradiction:

Improvecontrol logic capabilityVSAvoidconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent performs preliminary actions by providing a pre-configured graphical interface framework with templates and visual elements ready for use. Operators can quickly configure state machines by selecting and arranging graphical elements rather than building control logic from scratch, significantly reducing configuration time while maintaining full versatility through the flexible graphical configuration options.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The graphical interface allows operators to copy and reuse state machine configurations and graphical elements across different applications. This copying capability eliminates the need to reconfigure similar state machines repeatedly, dramatically reducing configuration time while preserving the ability to create custom, versatile control logic when needed.

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If programming languages or sequential function charts are used to track system status, then the system can implement complex control logic, but errors increase which can lead to serious safety issues

Engineering Contradiction:

Improvecontrol logic capabilityVSAvoidsystem safety

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The graphical user interface implements feedback mechanisms that automatically validate the state machine configuration as operators build it. The system provides real-time feedback on configuration errors, ensures logical consistency of state transitions, and prevents invalid configurations from being deployed. This feedback loop maintains full control logic versatility while dramatically improving reliability by catching errors before they can cause safety issues.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces error-prone manual coding mechanics with an automated graphical configuration system that inherently prevents many types of errors. The graphical interface enforces proper configuration through its structure, automatically generates validated control logic, and eliminates syntax errors and logical inconsistencies that commonly occur in manual programming, thereby maintaining versatility while improving safety and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS7730415B2State machine function block with a user modifiable state transition configuration database

Publication Date: 2010.06.01 FISHER ROSEMOUNT SYST INC

AI summary

A control system, a safety system, etc., within a process plant may each use one or more state machine function blocks that can be easily integrated into a function block diagram programming environment. Such a state machine function block may include one or more inputs, which may cause a state machine implemented by the state machine function block to change states. The state machine function block may determine a next state to which it is to transition based, at least in part, on data indicative of the next state to which to transition, if any. The configuration data may be retrieved from a database based on the current state of the state machine and at least one of the inputs. The state machine function block may also include one or more outputs that are generated based on the state of the state machine.