COLLECTING AND DELIVERING DATA TO A BIG DATA MACHINE IN A PROCESS CONTROL SYSTEM

• US 20170199843A1
• Filed: 03/27/2017
• Published: 07/13/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Muston, Paul Richard, Nixon, Mark J., Blevins, Terrence L., Christensen, Daniel D., Beoughter, Ken J.
• Granted Patent: US 10,037,303 B2
• Time in Patent Office: Days
• CPC Class Codes: G05B 13/0265 the criterion being a learning criterion
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31211 Communicate diagnostic data from intelligent field device controller to central
• CPC Class Codes: G05B 2219/31324 Distributed real time knowledge, database
• CPC Class Codes: G06F 15/173 using an interconnection network, e.g. matrix, shuffle, pyramid, star, snowflake
• CPC Class Codes: G06F 15/17331 Distributed shared memory [DSM], e.g. remote direct memory access [RDMA]
• CPC Class Codes: G06F 2212/2515 being configurable for different purposes, e.g. as cache or non-cache memory
• CPC Class Codes: G06F 9/54 Interprogram communication
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A device supporting big data in a process plant includes an interface to a communications network, a cache configured to store data observed by the device, and a multi-processing element processor to cause the data to be cached and transmitted (e.g., streamed) for historization at a unitary, logical centralized data storage area. The data storage area stores multiple types of process control or plant data using a common format. The device time-stamps the cached data, and, in some cases, all data that is generated or created by or received at the device may be cached and/or streamed. The device may be a field device, a controller, an input/output device, a network management device, a user interface device, or a historian device, and the device may be a node of a network supporting big data in the process plant. Multiple devices in the network may support layered or leveled caching of data.

Claims

1. A method of delivering data using a device communicatively coupled to a communications network of a process plant, the method comprising:

collecting, at the device, data corresponding to at least one of the process plant or a process controlled by physical equipment disposed in the process plant, the data including data that is at least one of generated by or received at the device, and the device being one of a field device or a controller;

storing, using a local schema, the collected data in a cache of the device; and

causing at least a portion of the collected data to be transmitted for storage at a data storage area of a process control big data appliance corresponding to the process plant, the data storage area being configured to store, using a common schema in which the local schema is included, multiple types of data from a set of types of data corresponding to at least one of the process plant or the process controlled by the process plant.

2. The method of claim 1, wherein the set of types of data includes at least two of continuous data, event data, measurement data, batch data, calculated data, or configuration data.

3. The method of claim 1, wherein collecting the data comprises at least one of:

collecting data that is generated by the device at a rate of generation or collecting data that is received at the device at a rate of reception.

4. The method of claim 1, wherein the data is first data and the device is a first device, and the method further comprises:

receiving, at the first device, second data that is at least one of generated by or received at a second device;

storing, using the local schema, the second data in the cache of the first device; and

causing at least a portion of the second collected data to be transmitted for storage in the data storage area of the process control big data appliance.

5. The method of claim 4, wherein:

the first device is the one of the field device or the controller and the second device is the other one of the field device or the controller; and

or the second device is an I/O device interconnecting the field device and the controller.

6. The method of claim 1, wherein:

storing the collected data in the cache includes storing, in conjunction with the collected data in the cache, indications of respective times of generation or reception of the collected data; and

causing the at least the portion of the collected data to be transmitted comprises causing the at least the portion of the collected data and the respective times of generation or reception of the at least the portion of the collected data to be transmitted.

7. The method of claim 6, wherein the at least the portion of the collected data and the respective times of generation or reception of the at least the portion of the collected data are stored, using the common schema, at the data storage area as time-series data, and wherein metadata corresponding to the time-series data is stored at the data storage area.

8. The method of claim 7, wherein the metadata is stored at the data storage area in a schema-less manner.

9. The method of claim 1, wherein causing the data to be transmitted comprises streaming the data using a stream control transmission protocol (SCTP).

10. A process control device for controlling a process in a process plant, the process control device comprising:

a cache configured to store, using a local schema, data including at least one of data generated by the process control device or data received by the process control device; and

a processor having at least one processing element designated to cause the data to be stored in the cache and to cause at least a portion of the data stored in the cache to be transmitted via a communications network for storage, using a common schema in which the local schema is included, at a data storage area corresponding to the process plant,

wherein the process control device is one of;

a field device configured to perform a physical function to control the process,

a controller configured to receive an input and generate, based on the input, an output to control the process, or

an input/output (I/O) device disposed between and communicatively connecting the field device and the controller.

11. The process control device of claim 10, wherein:

the at least one process element of the processor is a first at least one process element, and

a second at least one processing element of the processor is designated to operate the process control device to control the process in the process plant in real-time.

12. The process control device of claim 11, wherein the communications network is a first communication network, and wherein the second at least one processing element of the processor is designated to operate the process control device to control the process in real-time using a second communication network.

13. The process control device of claim 11, wherein the first at least one processing element and the second at least one processing element are mutually exclusive sets of processing elements of the processor.

14. The process control device of claim 10, wherein:

the data storage area is configured to store, using the common schema, multiple types of data corresponding to at least one of the process plant or the process controlled in the process plant; and

the multiple types of data are included in a set of types of data comprising continuous data, measurement data, event data, calculated data, configuration data, and batch data.

15. The process control device of claim 10, wherein the data is stored in the cache at a respective rate of generation or reception.

16. The process control device of claim 10, wherein the processor is configured to cause the at least the portion of the data stored in the cache to be streamed via the communications network.

17. The process control device of claim 10, wherein a configuration of the process control device excludes indications of one or more identities of data to be stored in the cache.

18. A system for supporting big data in a process plant, the system comprising:

a plurality of nodes interconnected via a communications network; and

a data storage area that is communicatively connected to the communications network and that is configured to store, using a common schema, multiple types of data from a set of data types corresponding to at least one of the process plant or a process being controlled by the process plant, the set of data types including continuous data, event data, measurement data, batch data, calculated data, and configuration data,

wherein each node of the plurality of nodes configured to (i) cache, using a respective local schema that is included in the common schema, data that is at least one of generated by or received at the each node, and to (ii) cause at least a portion of the cached data to be transmitted, via the communications network, to the data storage area for storage using the common schema.

19. The system of claim 18, wherein a first node of the plurality of nodes is further configured to (iii) receive second data that is at least one of generated by or received at a second node of the plurality of nodes, and to (iv) cause the second data to be transmitted for storage at the data storage area.

20. The system of claim 19, wherein the first node is disposed in the communications network between the second node and the storage area.

21. The system of claim 18, wherein the plurality of nodes includes at least two devices from a set of devices including:

a controller configured to receive a set of inputs, determine a value of an output, and cause the output to be transmitted to a first field device to control the process in the process plant, the first field device being configured to perform a physical function based on the output of the controller to control the process;

the first field device or a second field device;

an input/output (I/O) device having a field device interface and a controller interface;

a user interface device;

a gateway device;

an access point;

a routing device;

a historian device; and

a network management device.

22. The system of claim 18, wherein at least a portion of the plurality of nodes streams respective cached data to the data storage area via the communications network.