Open network-based data acquisition, aggregation and optimization for use with process control systems

• US 7,953,842 B2
• Filed: 02/19/2003
• Issued: 05/31/2011
• Est. Priority Date: 02/19/2003
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Eryurek, Evren, Dillon, Steven, Rome, Greg
• Primary Examiner(s): Vaughn, Jr.; William C
• Assistant Examiner(s): CHRISTENSEN, SCOTT B
• Application Number:
  US10/368,816
• Publication Number:
  US 20040162887A1
• Time in Patent Office: 3,023 Days
• Field of Search: 709/207, 709/227, 709/217, 709/204, 709/205, 709/219, 709/223, 709/229, 707/100, 707/104.1, 707/1
• US Class Current: 709/224
• 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 2219/34038 Web, http, ftp, internet, intranet server
• CPC Class Codes: H04L 67/10 in which an application is distributed across nodes in the network software deployment G06F8/60; multiprogramming arrangements G06F9/46
• CPC Class Codes: H04L 67/52 specially adapted for the location of the user terminal
• CPC Class Codes: H04W 4/02 Services making use of location information
• 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 system and method of collecting one of process control data and asset data from a plurality of data sources communicatively coupled to an open network stores location information associated with the plurality of data sources and periodically sends requests for process control information to each of the plurality of data sources by using the location information to communicate with each of the plurality of data sources via the open network. In addition, the system and method collects the process control data from messages received in response to the requests for process control information, aggregates the process control data to form aggregated process control data, and stores the aggregated process control data within a database. Additionally, the aggregated data is used in making decisions with regards to operation and maintenance of a process control system or a plant.

Claims

1. A method of receiving data from a plurality of process control system data sources communicatively coupled to an open network, the data comprising one of process control data and asset data, the method comprising:

storing location information identifying the plurality of process control system data sources,

wherein each of the process control system plurality of data sources includes a memory storing a software routine to communicate messages containing the data via the open network;

collecting, by the process control system, one of process control data or asset data based on the stored location information,

wherein collecting the one of process control data and asset data comprises;

polling the plurality of process control system data sources using the stored location information, and

receiving the messages containing the process control data and asset data via the open network;

determining one of process control data needed to make a process optimization decision or asset data needed to make an asset optimization decision for the process control system based on a system configuration stored in the process control system,

wherein the system configuration comprises configuration information detailing particular types of process control or asset information needed from the received plurality of messages;

stripping, from the received messages, the data determined to be needed based on the system configuration,

wherein one or more of the received messages include one or more of process control data and asset data that is determined to be not needed based on the system configuration,

discarding the process control data or asset data that is determined to be not needed;

aggregating the stripped data to form aggregated data;

storing the aggregated data within a process control or asset information database; and

one of

(a) optimizing a process using the aggregated data, and

(b) optimizing an asset using the aggregated data.

2. The method of claim 1, wherein receiving the messages via the open network includes periodically sending requests for information to each of the plurality of data sources by using the location information to communicate with each of the plurality of data sources via the open network.

3. The method of claim 2, wherein periodically sending the requests for information to each of the plurality of data sources by using the location information to communicate with each of the plurality of data sources via the open network includes retrieving uniform resource locators for each of the plurality of data sources from the location information and using the uniform resource locators to send extensible markup language messages to each of the plurality of data sources via an internet.

4. The method of claim 3, wherein using the uniform resource locators to send the extensible markup language messages to each of the plurality of data sources via the internet includes sending the extensible markup language messages to a plurality of web service interfaces, each of which is uniquely associated with one of the plurality of data sources.

5. The method of claim 1, wherein aggregating the data includes generating at least one aggregation field.

6. The method of claim 5, wherein generating the at least one aggregation field includes generating the at least one aggregation field based on one of a device type, a device age, a failure type, and a time-series characteristic.

7. The method of claim 1, further including summarizing the aggregated data prior to storing the aggregated data within the database.

8. The method of claim 1, further including automatically retrieving the location information from a data source registration service communicatively coupled to the open network.

9. The method of claim 8, wherein automatically retrieving the location information from the data source registration service communicatively coupled to the open network includes sending authorization information to the data source registration service via the open network.

10. The method of claim 9, wherein sending the authorization information to the data source registration service via the open network includes sending one of an enterprise name and a password to the data source registration service.

11. The method of claim 1, further comprising displaying the aggregated data.

12. A system for use in receiving data from a plurality of data sources communicatively coupled to an open network, the data comprising one of process control data and asset data, the system comprising:

a first database in a process control system storing location information identifying the plurality of data sources,

wherein each of the plurality of data sources includes a memory storing a software routine to communicate messages containing the data via the open network;

a data collection unit configured for collecting one of process control data or asset data based on the stored location information,

wherein collecting the one of process control data and asset data comprises;

polling the plurality of data sources using the stored location information, and

receiving the messages containing the process control data or asset data via the open network;

a data processing unit to identify the needed data to the data collection unit based on a system configuration stored in the process control system,

wherein the system configuration comprises configuration information detailing particular types of process control or asset information needed from the received messages,

wherein the data processing unit provides the system configuration to the data collection unit, and based on the received system configuration, the data collection unit strips, from the received messages, the identified needed data from the received messages,

wherein one or more of the received messages include one or more of process control data and asset data that is identified to be not needed based on the system configuration,

and the data collection unit discards the process control data or asset data that is identified to be not needed;

a data aggregation unit configured to aggregate the stripped data to form aggregated data;

a second database configured to store the aggregated data; and

an optimization unit to optimize one of a process or an asset using the stored aggregated data, the optimized process or asset including one or more of the process control system and a plant.

13. The system of claim 12, wherein the data collection unit that is adapted to periodically send requests for information to each of the plurality of data sources by using the location information to communicate with each of the plurality of data sources via the open network.

14. The system of claim 13, wherein the data collection unit is adapted to send request messages to each of the plurality of data sources via the open network at a fixed time interval.

15. The system of claim 14, wherein the data collection unit is adapted to retrieve uniform resource locators for each of the plurality of data sources from the location information and to use the uniform resource locators to send extensible markup language messages to each of the plurality of data sources via an internet.

16. The system of claim 15, wherein data collection unit is adapted to send the extensible markup language messages to a plurality of web service interfaces, each of which is uniquely associated with one of the plurality of data sources.

17. The system of claim 13, wherein the data aggregation unit is adapted to generate at least one aggregation field.

18. The system of claim 17, wherein the data aggregation unit is adapted to generate the at least one aggregation field based on one of a device type, a device age, a failure type, and a time-series characteristic.

19. The system of claim 13, further including a data summarization unit that is adapted to summarize the aggregated data prior to storing the aggregated process control data within the second database.

20. The system of claim 13, further including a data source registration service communicatively coupled to the open network and adapted to send the location information to the first database.

21. The system of claim 13, further comprising a display unit to display the aggregated data.

22. A system for collecting data from a plurality of data sources communicatively coupled to an open network, the data comprising one of process control data and asset data, the system comprising:

a non-transitory computer readable medium; and

software stored on the computer readable medium and adapted to be executed by a processor to perform a method, the method comprising;

storing location information identifying the plurality of process control system data sources,

wherein each of the process control system plurality of data sources includes a memory storing a software routine to communicate messages containing the data via the open network;

collecting, by the process control system, one of process control data or asset data based on the stored location information,

wherein collecting the one of process control data and asset data comprises;

polling the plurality of process control system data sources using the stored location information, and

receiving the messages containing the process control data and asset data via the open network;

determining one of process control data needed to make a process optimization decision or asset data needed to make an asset optimization decision for the process control system based on a system configuration stored in the process control system,

wherein the system configuration comprises configuration information detailing particular types of process control or asset information needed from the received plurality of messages;

stripping, from the received messages, the data determined to be needed based on the system configuration,

wherein one or more of the received messages include one or more of process control data and asset data that is determined to be not needed based on the system configuration,

discarding the process control data or asset data that is determined to be not needed;

aggregating the stripped data to form aggregated data;

storing the aggregated data within a process control or asset information database; and

one of

(a) optimizing a process using the aggregated data, and

(b) optimizing an asset using the aggregated data.

23. The system of claim 22, wherein the software is further adapted to periodically send request for information to each of the plurality of data sources by using the location information to communicate with each of the plurality of data sources via the open network.

24. The system of claim 23, wherein the software is further adapted to be executed by the processor to retrieve uniform resource locators for each of the plurality of data sources from the location information and to use the uniform resource locators to send extensible markup language messages to each of the plurality of data sources via the Internet.

25. The system of claim 24, wherein the software is further adapted to be executed by the processor to send the extensible markup language messages to a plurality of web service interfaces, each of which is uniquely associated with one of the plurality of data sources.

26. The system of claim 23, wherein the software is further adapted to be executed by the processor to generate at least one aggregation field.

27. The system of claim 26, wherein the software is further adapted to be executed by the processor to generate the at least one aggregation field based on one of a device type, a device age, a failure type, and a time-series characteristic.

28. The system of claim 23, wherein the software is further adapted to be executed by the processor to summarize the aggregated data prior to storing the aggregated data within the database.

29. The system of claim 23, wherein the software is further adapted to be executed by the processor to automatically retrieve the location information from a data source registration service communicatively coupled to the open network.

30. The system of claim 23, wherein the software is further adapted to be executed by the processor to send authorization information to the data source registration service via the open network.

31. The system of claim 30, wherein the software is further adapted to send one of an enterprise name and a password to the data source registration service via the open network.

32. A method of retrieving data from a plurality of process control system data sources, the data comprising one of process control data and asset data, the method comprising:

storing network address information identifying the plurality of process control system data sources,

wherein each of the plurality of data sources includes a memory storing a software routine to communicate messages containing the data via the open network;

collecting, by the process control system, one of process control data or asset data based on the stored network address information,

wherein collecting the one of process control data or asset data comprises;

polling the plurality of data sources using the stored location information, and

receiving the messages containing the one of process control data or asset data via the open network;

determining one of process control data needed to make a process optimization decision or asset data needed to make an asset optimization decision for the process control system based on a system configuration stored in the process control system,

wherein the system configuration comprises configuration information detailing particular types of process control or asset information needed from the received plurality of messages;

stripping, from the received messages, the data determined to be needed based on the system configuration,

wherein one or more of the received messages include one or more of process control data and asset data that is determined to be not needed based on the system configuration;

discarding the process control data or asset data that is determined to be not needed;

aggregating the stripped data to form aggregated data;

storing the aggregated data within a process control or asset information database; and

one of

(a) optimizing a process using the aggregated data, and

(b) optimizing an asset using the aggregated data.

33. The method of claim 32, wherein retrieving the network address information from the database includes requesting the network address information from a data source registration service and receiving messages containing the network address information from the data source registration service via the open network.

34. The method of claim 32, wherein using the network address information to send the request messages to the data sources via the open network and the respective web service interfaces of the data sources includes repeatedly sending the request messages to the data sources.

35. A system for retrieving data from a plurality of data sources, the data comprising one of process control data and asset data, the system comprising:

a non-transitory computer readable memory; and

software stored on the computer readable memory and adapted to be executed by a processor to perform a method, the method comprising;

storing network address information identifying the plurality of process control system data sources,

wherein each of the plurality of data sources includes a memory storing a software routine to communicate messages containing the data via the open network;

collecting, by the process control system, one of process control data or asset data based on the stored network address information,

wherein collecting the one of process control data or asset data comprises;

polling the plurality of data sources using the stored location information, and

receiving the messages containing the one of process control data or asset data via the open network;

determining one of process control data needed to make a process optimization decision or asset data needed to make an asset optimization decision for the process control system based on a system configuration stored in the process control system,

wherein the system configuration comprises configuration information detailing particular types of process control or asset information needed from the received plurality of messages;

stripping, from the received messages, the data determined to be needed based on the system configuration,

wherein one or more of the received messages include one or more of process control data and asset data that is determined to be not needed based on the system configuration;

discarding the process control data or asset data that is determined to be not needed;

aggregating the stripped data to form aggregated data;

storing the aggregated data within a process control or asset information database; and

one of

(a) optimizing a process using the aggregated data, and

(b) optimizing an asset using the aggregated data.

36. The system of claim 35, wherein the software is further adapted to be executed by the processor to request the network address information from a data source registration service and to receive messages containing the network address information from the data source registration service via the open network.

37. The system of claim 35, wherein the software is further adapted to be executed by the processor to repeatedly send the request messages to the data sources.