Integrated advanced control blocks in process control systems
First Claim
1. A process control element adapted to be used as a portion of a process control routine implemented on a processor to control a process, the process control element comprising:
- a computer readable medium;
an advanced control function block stored on the computer readable medium and adapted to be executed on the processor to implement multiple-input/multiple output control of a process, the advanced control function block including, a first plurality of inputs, wherein each input is adapted to receive a different one of a set of process parameters;
a second plurality of outputs, wherein each output is adapted to be communicatively coupled to a different process input for controlling the set of process parameters; and
control logic responsive to the first plurality of inputs to produce a control signal at each of the second plurality of outputs.
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Accused Products
Abstract
An advanced control block that implements multiple-input/multiple-output control, such as model predictive control, within a process control system is initiated by creating an initial control block having generic control logic and desired control inputs and control outputs communicatively connected to process outputs and process inputs within a process control routine. A waveform generator within the control block systematically upsets each of the process inputs via the control block outputs using excitation waveforms designed for use in developing a process model. At the same time, a data collection routine collects data indicating the response of each of the process outputs to the waveforms delivered at each of the process inputs. After sufficient data has been collected, a process modeling routine generates a process model from the collected data and a control logic parameter creation routine creates control logic parameters for the control logic from the process model. The control logic parameters and the process model are then downloaded to the control block to complete formation of the advanced control block. Thereafter, the advanced control block is used to provide advanced process control within the process control routine. Likewise, the process model is used to provide simulation of the process or to produce virtual process outputs.
323 Citations
60 Claims
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1. A process control element adapted to be used as a portion of a process control routine implemented on a processor to control a process, the process control element comprising:
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a computer readable medium;
an advanced control function block stored on the computer readable medium and adapted to be executed on the processor to implement multiple-input/multiple output control of a process, the advanced control function block including, a first plurality of inputs, wherein each input is adapted to receive a different one of a set of process parameters;
a second plurality of outputs, wherein each output is adapted to be communicatively coupled to a different process input for controlling the set of process parameters; and
control logic responsive to the first plurality of inputs to produce a control signal at each of the second plurality of outputs. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A process control element adapted to be used as a portion of a process control routine implemented on a processor to control a process, the process control element comprising:
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a computer readable medium;
an advanced control function block stored on the computer readable medium and adapted to be executed on the processor including, a first plurality of inputs, wherein each input is adapted to receive a different one of a set of process parameters;
a second plurality of outputs, wherein each output is adapted to be communicatively coupled to a different process input for controlling the set of process parameters;
a waveform generator adapted to generate process excitation waveforms at each of the plurality of outputs; and
a data collection unit adapted to coordinate the collection of data representing signal values at each of the plurality of inputs when the waveform generator generates the process excitation waveforms at each of the plurality of outputs. - View Dependent Claims (18, 19, 20, 21, 22, 23)
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24. A method of developing an advanced control element for use in a process control routine that controls a process, the method comprising the steps of:
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providing an advanced control element having a first plurality of control inputs adapted to receive process outputs of the process and having a second plurality of control outputs adapted to provide control signals to process inputs of the process;
communicatively connecting the advanced control element within the process control routine;
using the advanced control element to provide excitation waveforms to each of the process inputs;
using the advanced control element to collect data reflecting the response of each of the process outputs to the excitation waveforms;
creating a process model from the collected data;
developing advanced control logic parameters from the process model; and
placing the advanced control logic parameters within the advanced control element for use by the advanced control element to control the process. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42)
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43. An advanced control element development system adapted to develop an advanced control element for use in a process control routine that is executed within a process control system, the advanced control element development system including:
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a computer readable medium;
a first routine stored on the computer readable medium and adapted to be executed on a processor that creates an advanced control element having a first plurality of control inputs adapted to receive process outputs and having a second plurality of control outputs adapted to provide control signals to process inputs;
a second routine stored on the computer readable medium and adapted to be executed on a processor that enables a user to communicatively connect the advanced control element within the process control routine;
a third routine stored on the computer readable medium and adapted to be executed on a processor that uses the advanced control element to provide excitation waveforms to each of the process inputs;
a fourth routine stored on the computer readable medium and adapted to be executed on a processor that uses the advanced control element to collect data reflecting the response of each of the process outputs to the excitation waveforms;
a fifth routine stored on the computer readable-medium and adapted to be executed on a processor that creates a process model from the collected data;
a sixth routine stored on the computer readable medium and adapted to be executed on a processor that develops advanced control logic parameters from the process model; and
a seventh routine stored on the computer readable medium and adapted to be executed on a processor that places the advanced control logic parameters within the advanced control element to enable the advanced control logic element to control the process. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52)
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53. A method of using a multiple-input/multiple output advanced control element capable of controlling a process, wherein the advanced control element was is based on a process model developed for the process, the method comprising the steps of:
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generating a process simulation element from the process model;
communicatively connecting the process simulation element to the advanced control element; and
using the advanced control element to control the process simulation element. - View Dependent Claims (54, 55, 56, 57, 58, 59, 60)
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Specification