Systems and methods for real-time control

• US 10,394,205 B2
• Filed: 11/21/2017
• Issued: 08/27/2019
• Est. Priority Date: 11/29/2016
• Status: Active Grant

• Current Assignee: Virtual Peaker, Inc.
• Original Assignee: Virtual Peaker, Inc.
• Inventors: Burke, William J.
• Primary Examiner(s): Lee, Thomas C
• Assistant Examiner(s): Cai, Charles
• Application Number:
  US15/818,864
• Publication Number:
  US 20180150040A1
• Time in Patent Office: 644 Days
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31101 Configuration file with format of relevant messages for different equipment
• CPC Class Codes: H04L 67/02 based on web technology, e.g. hypertext transfer protocol [HTTP]
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Systems and methods for real time control are provided. One embodiment includes executing a first control cycle that includes retrieving an input message, where the input message includes an identifier of a network device with an input and an actuator and retrieving a context object that includes a serialized controller data structure from a previous control sample. The first control cycle may additionally include retrieving data related to the input for the network device and bundle the data related to the input with the serialized controller data structure into a run message, de-serializing the serialized controller data structure, and using the controller data structure in conjunction with the data related to the input to determine a new actuator position of the actuator. In some embodiments, the first control cycle includes updating and serializing the controller data structure and causing the actuator to be set to the new actuator position.

Claims

1. A method for real time control comprising:

executing, by a first computing device, a first control cycle that includes at least the following;

retrieving an input message, wherein the input message includes an identifier of a network device that includes an input and an actuator;

retrieving a context object from the identifier in the input message that includes a serialized controller data structure from a previous control sample of the network device and a list of required inputs for the control system;

gathering new inputs for the control system based on the requirements in the context object and bundling the new inputs with the serialized controller data structure into a run message;

de-serializing the serialized controller data structure;

using the controller data structure in conjunction with the new inputs to determine a new actuator position of the actuator;

updating and serializing the controller data structure; and

causing the actuator to be set to the new actuator position; and

executing, by a second computing device, a second control cycle for the network device.

2. The method of claim 1, further comprising causing a timer to begin the first control cycle.

3. The method of claim 1, further comprising using a hypertext transfer protocol request to begin the first control cycle.

4. The method of claim 1, further comprising:

creating, by the first computing device, an output message that includes the new actuator position and the updated controller data structure; and

sending the output message to an output queue.

5. The method of claim 1, further comprising storing, by the first computing device, the updated controller data structure.

6. The method of claim 1, further comprising calculating a time for beginning the second control cycle from within the first control cycle.

7. The method of claim 1, further comprising, adjusting by the network device, the actuator to the new actuator position.

8. A system for real time control comprising:

a network device that includes an actuator and an input; and

a first computing device that is remotely located from the network device and includes a memory component and a processor, wherein the memory component stores at least the following for executing a control cycle of the network device;

input queue worker logic that, when executed by the processor causes the system to perform at least the following;

retrieve an input message from an input queue, wherein the input message includes an identifier of the network device;

retrieve a context object identified from the identifier in the input message, wherein the context object includes a serialized controller data structure from a previous control sample of the network device and wherein the context object includes an identification of the input for the network device;

gather new inputs for the control system based on the requirements in the context object and bundle the new inputs with the serialized controller data structure into a run message; and

place the run message into a run queue;

run queue worker logic that, when executed by the processor causes the system to perform at least the following;

de-serialize the serialized controller data structure;

use the controller data structure in conjunction with the new inputs to determine a new actuator position of the actuator;

update and serialize the controller data structure;

create an output message that includes the new actuator position and the updated controller data structure; and

send the output message to an output queue;

output queue worker logic that, when executed by the processor, causes the system to perform at least the following;

retrieve the output message from the output queue;

cause the actuator to be set to the new actuator position; and

store the updated controller data structure.

9. The system of claim 8, wherein a subsequent control cycle for the network device is run on a second computing device that is different than the first computing device.

10. The system of claim 8, wherein at least one of the following is a first-in-first-out queue:

the input queue, the run queue or the output queue.

11. The system of claim 8, wherein the control cycle is initiated via a self-starting timer.

12. The system of claim 8, wherein the input message further includes a timer to begin the control cycle.

13. The system of claim 8, wherein at least one of the following operates as a hypertext transfer protocol request:

the input queue, the run queue or the output queue.

14. The system of claim 8, further comprising a remote database, wherein the serialized controller data structure is retrieved from the remote database.

15. A system for real time control comprising:

a first server that is communicatively coupled to a network device that includes an actuator and an input, wherein the first server includes a first memory component and a first processor, wherein the first memory component stores logic for executing a first control cycle for the network device that, when executed by the first processor, causes the system to perform at least the following;

retrieve an input message, wherein the input message includes an identifier of the network device;

retrieve a context object using the identifier from the input message that includes a serialized controller data structure from a previous control sample of the network device, wherein the context object includes an identification of the input for the network device;

gather new inputs for the control system based on the requirements in the context object and bundle the data related to the input with the serialized controller data structure into a run message;

use the controller data structure in conjunction with the new inputs to determine a new actuator position of the actuator;

update the controller data structure;

cause the actuator to be set to the new actuator position; and

store the updated controller data structure; and

a second server that is communicatively coupled to the network device that includes a second memory component and a second processor, wherein the second memory component stores logic that, when executed by the second processor, causes the system to execute a second control cycle for the network device.

16. The system of claim 15, wherein the logic further causes the system to perform at least the following:

create an output message that includes the new actuator position and the updated controller data structure; and

send the output message to an output queue.

17. The system of claim 15, wherein the logic further causes a timer to begin the first control cycle.

18. The system of claim 15, further comprising a remote database, wherein the serialized controller data structure is retrieved from the remote database.

19. The system of claim 15, further comprising the network device.

20. The system of claim 15, wherein the logic further causes the system to calculate a time for beginning the second control cycle from within the first control cycle.