System and methods for the universal integration of plant floor assets and a computerized management system

• US 10,114,367 B2
• Filed: 09/04/2015
• Issued: 10/30/2018
• Est. Priority Date: 04/26/2007
• Status: Active Grant

• Current Assignee: Aspentech Corporation
• Original Assignee: Mtelligence Corporation (Aspentech Corporation)
• Inventors: Bates, Alex, Rahilly, Paul, Macnab, Scott, Brooks, Gordon
• Primary Examiner(s): Springer, James E
• Application Number:
  US14/846,553
• Publication Number:
  US 20160187872A1
• Time in Patent Office: 1,152 Days
• Field of Search: 709224
• CPC Class Codes: G05B 13/02 electric
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/31391 Administration tasks and factory control tasks
• CPC Class Codes: H04L 41/0213 Standardised network management protocols, e.g. simple network management protocol [SNMP]
• CPC Class Codes: H04L 41/0226 Mapping or translating multiple network management protocols
• CPC Class Codes: H04L 41/06 Management of faults, events, alarms or notifications
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A server platform and a method to integrate a plurality of diverse plant floor equipment with at least one computerized management system in a manufacturing operational or maintenance system. The server platform includes a plurality of plant floor drivers adapted to communicatively interface with a plurality of diverse plant floor data sources. The server platform further includes at least one computerized management system driver adapted to communicatively interface with the at least one computerized management system. The server platform also includes a message translator adapted to broker communication between the plant floor data sources and the at least one computerized management system using an open standard. The server platform, using the open standard, enables a universal enterprise type taxonomy across the plant floor data sources and the at least one computerized management system.

Claims

1. A server platform for integrating a plurality of diverse plant floor equipment with at least one computerized management (CM) system, said server platform comprising:

a processor;

a memory;

a plurality of plant floor drivers adapted to interface with a plurality of diverse plant floor data sources, the plurality of plant floor drivers configured to establish first communication links between said server platform and the plurality of diverse plant floor data sources, the plurality of diverse plant floor data sources configured to access information from a plurality of diverse plant floor equipment;

at least one CM system driver adapted to interface with said at least one CM system, said at least one CM system driver configured to establish a second communication link between said server platform and said at least one CM system;

a discovery application configured to;

discover from said plurality of diverse plant floor data sources, via said first communication links, at least one of a device object of a plurality of defined device objects and a device type of a plurality of defined device types, and import the discovered at least one of device object and device type into said server platform; and

discover from said at least one CM system, via said second communication link, at least one of a management object of a plurality of defined management objects and a management type of a plurality of defined management types, and import the discovered at least one of management object and management type into said server platform; and

one or more mapping applications configured to generate one or more mappings that relate (i) the imported at least one of device object and device type to (ii) said imported at least one of management object and management type.

2. The server platform of claim 1 further comprising:

a message translator adapted to, based on said generated one or more mappings, associate portions of first information from a diverse plant floor data source with portions of second information from said at least one CM system,

the message translator includes a semantic model forming an open object metadata registry capable of enabling a universal enterprise type taxonomy across said plurality of diverse plant floor data sources and said at least one CM system.

3. The server platform of claim 2 further comprising a mapper database adapted to store semantic mappings and non-semantic mappings between said plurality of diverse plant floor data sources and said at least one CM system, such that said message translator is capable of accessing said semantic and non-sematic mappings to facilitate said message translator to associate said portions of first information from a diverse plant floor data source with said portions of second information from at least one CM system.

4. The server platform of claim 1 wherein said at least one CM system comprises one of a computerized maintenance management system (CMMS) and an enterprise asset management (EAM) system.

5. The server platform of claim 1 wherein said plurality of diverse plant floor data sources include at least one of an asset health system, condition monitoring sensors, and a plant historian system.

6. The server platform of claim 1 wherein the one or more mapping applications employ a plurality of universal identifiers defined in an open standard and said open standard comprises the MIMOSA open standard.

7. The server platform of claim 6

wherein the one or more mapping applications are configured to generate the one or more mappings at least in part by mapping an imported device object to a universal identifier of the plurality of universal identifiers and mapping an imported device type to said universal identifier.

8. The server platform of claim 7 further comprising a contextualizing application adapted to semantically map imported device types to pre-defined open standard universal type identifiers.

9. The server platform of claim 7 further comprising an assigning application adapted to assign first universal object identifiers to imported device objects and second universal object identifiers to imported management objects defined by said at least one CM system.

10. The server platform of claim 1 further comprising a condition based maintenance application adapted to generate maintenance work orders in response to first information collected from said plurality of diverse plant floor data sources and second information collected from said at least one CM system.

11. The server platform of claim 1 further comprising a performance measurement application adapted to track key performance indicators in response to first information collected from said plurality of diverse plant floor data sources and second information collected from said at least one CM system.

12. The server platform of claim 1 wherein communication with said plurality of diverse plant floor data sources is accomplished via at least one of open communication protocols and proprietary communication protocols.

13. The server platform of claim 1 wherein communication with said at least one CM system is accomplished via a web services protocol.

14. A method of integrating a plurality of diverse plant floor equipment with at least one computerized management (CM) system, said method comprising:

establishing, via a plurality of plant floor adapters of a server platform, first communication links between said server platform and a plurality of diverse plant floor data sources, the plurality of diverse plant floor data sources configured to access information from a plurality of diverse plant floor equipment;

establishing, via at least one CM system adapter of said server platform, a second communication link between said server platform and at least one computerized management (CM) system;

discovering, via said first communication links, at least one of a device object of a plurality of defined device objects and a device type of a plurality of defined device types from said plurality of plant floor data sources, and importing the discovered at least one of device object and device type into said server platform;

discovering, via said second communication link, at least one of a management object of a plurality of defined management objects and a management type of a plurality of defined management types from said at least one CM system, and importing the discovered at least one of management object and management type into said server platform; and

generating one or more mappings that relate (i) the imported at least one of device object and device type to (ii) said imported at least one of management object and management type.

15. The method of claim 14 wherein said generating includes semantically contextualizing imported device types and imported management types to pre-defined open standard universal type identifiers within said server platform.

16. The method of claim 15 wherein said semantic contextualizing includes:

automatically sorting at least one of imported device types and imported management types, having a first ordinal scale, by ordinality;

automatically sorting said universal type identifiers, having a second ordinal scale, by ordinality; and

automatically assigning said sorted at least one of imported device types and imported management types to said sorted universal type identifiers by applying an inference algorithm.

17. The method of claim 16 wherein said inference algorithm includes a histogram technique.

18. The method of claim 15 wherein said semantic contextualizing includes:

automatically sorting at least one of imported device types and imported management types, having a first nominal scale, by frequency of occurrence;

automatically sorting said universal type identifiers, having a second nominal scale, based on a pre-defined rate of occurrence; and

automatically assigning said sorted at least one of imported device types and imported management types to said sorted universal type identifiers by applying an inference algorithm.

19. The method of claim 18 wherein said inference algorithm includes a heuristic technique.

20. The method of claim 18 wherein said frequency of occurrence is determined from a work history stored within said server platform.

21. The method of claim 14 wherein said generating includes assigning imported device objects and imported management objects to globally unique identifiers within said server platform.

22. The method of claim 14 wherein said generating includes semantically associating imported management objects to universal type identifiers within said server platform.

23. The method of claim 14 wherein said at least one CM system comprises one of a computerized maintenance management system (CMMS) and an enterprise asset management (EAM) system.

24. The method of claim 14 wherein said first communication links are adapted to use at least one of open communication protocols and proprietary communication protocols.

25. The method of claim 24 wherein said protocols include at least one of an open connectivity protocol, a modbus protocol, an XML web services protocol, and a proprietary protocol.

26. The method of claim 14 wherein said second communication link is adapted to use a web services protocol.

27. The method of claim 26 wherein said web services protocol includes a MIMOSA OSA-EAI Tech-XML-services web services protocol.

28. The method of claim 14 wherein said plurality of defined device and/or management objects include at least one of assets, segments, agents, measurement points, enterprise, and site.

29. The method of claim 14 wherein one or more of said plurality of defined device types and said plurality of defined management types include at least one of an asset type, a work type, a priority type, an asset priority type, an alarm severity type, an ordinal health type, a work priority type, and a problem code type.

30. The method of claim 14 wherein said plurality of defined device types include at least one of an alarm severity type, an asset criticality type, a health type, a problem type, a failure type, and a remedy type.

31. The method of claim 14 wherein said plurality of defined management types includes at least one of an asset type, a work priority type, an asset criticality type, a health type, a problem type, a failure type, and a remedy type.

32. The method of claim 14 further comprising associating portions of first information from said diverse plant floor data sources via the first communication links with portions of second information from said at least one CM system via the second communication link.

33. The method of claim 32 further comprising automatically triggering at least one work flow in response to said associated portions.

34. The method of claim 33 wherein said work flow comprises at least one of an audit work status work flow, an escalate priority work flow, a synchronize asset data work flow, a production asset capability forecast work flow, and a measure performance work flow.

35. The method of claim 32 further comprising automatically generating at least one work order in response to said associated portions.

36. The method of claim 35 wherein said at least one work order comprises an automated condition-based maintenance work order.

37. The method of claim 36 wherein said automated condition-based maintenance work order comprises at least one of a predictive maintenance work order, a corrective maintenance work order, a preventive maintenance work order, and an emergency maintenance work order.

38. The method of claim 32 further comprising automatically tracking at least one key performance indicator in response to said associated portions.