Analytical server integrated in a process control network

• US 8,046,096 B2
• Filed: 05/19/2010
• Issued: 10/25/2011
• Est. Priority Date: 10/04/2005
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Mehta, Ashish, Lewis, Marty James, Denison, David R., Wojsznis, Peter
• Primary Examiner(s): Bahta; Kidest
• Application Number:
  US12/782,946
• Publication Number:
  US 20100228363A1
• Time in Patent Office: 524 Days
• Field of Search: 700/1, 700/9, 700/11, 700/28, 700/29, 700/83, 700/52, 700/100, 700107-109, 700/117, 700/167, 700/204, 700/266, 347/12, 347/41, 347/310.11, 703/174, 702/138, 702/145, 702113-115, 701/25, 701/35, 701/29, 701/31
• US Class Current: 700/117
• CPC Class Codes: G05B 13/0275 using fuzzy logic only
• CPC Class Codes: G05B 13/042 in which a parameter or coefficient is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 13/048 using a predictor
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/31378 Queue control
• CPC Class Codes: G05B 2219/31422 Upload, download programs, parameters from, to station to, from server
• 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 process control system integrates the collection and analysis of process control data used to perform certain computationally expensive process control functions, like adaptive model generation and tuning parameter generation, in the same control device in which one or more of the process control routines are implemented, to thereby provide for faster and more efficient support of the process control routines. This system replaces a layered approach using multiple processing devices by integrating an analytical server which performs computationally expensive analyses used by one or more control routines directly into the real-time control device in which the one or more control routines are located. This integration provides the ability to analyze large quantities of data for multiple process loops controlled by a particular device in a fast and efficient manner.

Claims

1. A method of controlling a process, comprising:

implementing a process control routine within a process control device by executing the process control routine on a processor of the process control device to implement on-line process control operations with respect to the process;

implementing a server routine in the process control device, the server routine including a support algorithm, including executing the server routine on a processor of the process control device;

using the process control routine to collect real-time process data;

making one or more calls from the process control routine to the server routine;

sending the collected process data to the server routine as part of one of the calls;

running the support algorithm within the server routine on the collected process data associated with the process control routine to generate controller data in response to each of the one or more calls from the process control routine; and

using the generated controller data in the process control routine to effect the manner in which the process control routine implements the on-line process control operations.

2. The method of claim 1, including executing the server routine asynchronously with respect to executing the process control routine.

3. The method of claim 1, wherein running the support algorithm includes executing a process model generation routine to create a process model.

4. The method of claim 1, including using the process control routine to collect further real-time process data for a subsequent call to the server while the server routine is running the support algorithm on the collected real-time process data sent as part of the first one of the calls.

5. The method of claim 1, further including sending the controller data from the server routine to a second device external to the process control device.

6. The method of claim 1, including simultaneously processing multiple calls from the process control routine via the server routine.

7. The method of claim 6, including determining an order in which to process the multiple calls based on priority information associated with the multiple calls.

8. The method of claim 6, including processing the multiple calls at the server routine using a queue.

9. The method of claim 1, wherein executing the process control routine on the processor of the process control device to implement on-line process control operations with respect to the process includes executing the process control routine on a processor once every execution period associated with the process control routine, and wherein making the one or more calls from the process control routine to the server routine includes making a call from the process control routine to the server routine less than once every execution period associated with the process control routine.

10. The method of claim 1, including executing the process control routine on the same processor as the server routine.

11. The method of claim 1, including executing the process control routine on a first processor disposed within a control device and executing the server routine on a second processor disposed within the control device, wherein the second processor is separate from the first processor.

12. A method of controlling a process, comprising:

implementing multiple process control routines within a single process control device by executing the multiple process control routines on a processor of the process control device to implement multiple on-line process control operations with respect to the process;

implementing a server routine in the process control device, the server routine including a support algorithm, including executing the server routine on a processor of the process control device;

collecting real-time process data at one of the multiple control routines;

making at least one call from each of the multiple process control routines to the server routine at different times;

sending the collected real-time process data to the server routine as part of a call from the one of the multiple process control routines;

in response to each of the calls from the multiple process control routines, running the support algorithm within the server routine on the collected process data associated with one of the multiple process control routines to generate controller data for the one of the multiple process control routines; and

using the generated controller data generated by the server routine in the multiple process control routines to effect the manner in which the multiple process control routines implement the on-line process control operations.

13. The method of claim 12, including executing the server routine on a processor of the process control device asynchronously with respect to executing the multiple process control routines on a processor of the process control device.

14. The method of claim 12, wherein running the support algorithm includes executing a process model generation routine to create a process model.

15. The method of claim 12, including using the server routine to simultaneously process multiple calls from different ones of the multiple process control routines.

16. The method of claim 15, including determining an order in which to process the multiple calls based on priority information associated with the multiple calls.