Method and system of protection of technological equipment

• US 9,395,713 B2
• Filed: 05/05/2014
• Issued: 07/19/2016
• Est. Priority Date: 05/05/2014
• Status: Active Grant

• Current Assignee: IP Research LLC
• Original Assignee: IP Research LLC
• Inventors: Grigoryev, Viacheslav
• Primary Examiner(s): Lo, Kenneth M
• Assistant Examiner(s): Lin, Jason
• Application Number:
  US14/269,611
• Publication Number:
  US 20150316898A1
• Time in Patent Office: 806 Days
• Field of Search: 700/81, 700/29, 700/44, 700/160, 700/173, 428/411.1
• US Class Current: 1/1
• CPC Class Codes: G05B 19/0425 Safety, monitoring
• CPC Class Codes: G05B 19/4069 Simulating machining process on screen G05B19/4068 takes precedence
• CPC Class Codes: G05B 9/02 electric

Abstract

Disclosed are systems, methods, and computer program products for automatic monitoring of the performance of a technological process at industrial facilities. An example method for protecting technological equipment comprises: receiving control parameters of an operation for adoption by actuating elements of an equipment; establishing a range of values for at least one performance factor of the operation; determining a value of the at least one performance factor based on the control parameters; comparing the value of the at least one performance factor with the range of values; determining based on the comparison whether the value of the at least one performance factor is outside the range of values; and preventing the adoption of the control parameters by the actuating elements if it is determined that the value of the at least one performance factor is outside the range of values.

Claims

1. A method for protecting processing equipment of at least one actuating element by determining whether control parameters for the processing equipment comply with valid control parameters, the method comprising:

modeling a plurality of performance factors of at least one actuating element based on a plurality of sets of the valid control parameters, respectively;

storing, in a database, the modeled performance factors and the plurality of sets of valid control parameters;

intercepting control parameters output from a controller and intended to control the processing equipment of the at least one actuating element before the control parameters are received by the intended processing equipment;

determining whether the intercepted control parameters match any of the valid control parameters stored in the database and, upon a match, accessing a corresponding modeled performance factor for the matched valid control parameters;

accessing, from the database, a predetermined range of values for a permissible performance factor of the at least one actuating element;

comparing the accessed modeled performance factor with the range of values for the permissible performance factor;

if the intercepted control parameters do not match any of the valid control parameters stored in the database, selecting a mathematical model to calculate a predictive performance factor of the least one actuating element based on the intercepted control parameters and comparing the predictive performance factor with the range of values for the permissible performance factor;

preventing the intercepted control parameters from being input to the processing equipment of the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is outside the range of values for the permissible performance factor; and

allowing the intercepted control parameters to be inputted into the processing equipment to control the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is within the range of values for the permissible performance factor.

2. The method of claim 1, further comprising storing in the database a plurality of values of the calculated predictive performance factor by the selected mathematical model for a plurality of values of the control parameters.

3. The method of claim 1, wherein the calculating of the value of the performance factor comprises synchronous modeling the value for continuous prevention of controlling the at least one actuating element when the calculated performance factor is outside the range of values.

4. The method of claim 3, wherein the synchronous modeling comprises:

for the control parameters values previously used for mathematical modeling the value stored in a database, retrieving the value from the database; and

for the control parameters values not used for mathematical modeling the value stored in the database, obtaining the value by modeling the equipment for the control parameters values.

5. The method of claim 1, wherein intercepting the control parameters further comprises at least one of intercepting the control parameters when the control parameters are entered into a system by an operator and intercepting the control parameters when the control parameters are transmitted to a zone of the actuating elements.

6. A system for protecting technological processing equipment of at least one actuating element by determining whether control parameters for the processing equipment comply with valid control parameters, the system comprising:

a hardware processor configured to;

model a plurality of performance factors of at least one actuating element based on a plurality of sets of the valid control parameters, respectively;

store, in a database, the modeled performance factors and the plurality of sets of valid control parameters;

intercept control parameters output from a controller and intended to control the processing equipment of the at least one actuating element before the control parameters are received by the intended processing equipment;

determine whether the intercepted control parameters match any of the valid control parameters stored in the database and, upon a match, access a corresponding modeled performance factor for the matched valid control parameters;

access, from the database, a predetermined range of values for a permissible performance factor of the at least one actuating element;

compare the accessed modeled performance factor with the range of values for the permissible performance factor;

if the intercepted control parameters do not match any of the valid control parameters stored in the database, select a mathematical model to calculate a predictive performance factor of the least one actuating element based on the intercepted control parameters and compare the predictive performance factor with the range of values for the permissible performance factor;

prevent the intercepted control parameters from being input to the processing equipment of the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is outside the range of values for the permissible performance factor; and

allow the intercepted control parameters to be inputted into the processing equipment to control the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is within the range of values for the permissible performance factor.

7. The system of claim 6, wherein the processor further configured to store in the database a plurality of values of the calculated predictive performance factor by the selected mathematical model for a plurality of values of the control parameters.

8. The system of claim 6, wherein the calculating of the value of the performance factor comprises synchronous modeling the value for continuous prevention of controlling the at least one actuating element when the calculated performance factor is outside the range of values.

9. The system of claim 8, wherein the synchronous modeling comprises:

for the control parameters values previously used for mathematical modeling the value stored in a database, retrieving the value from the database; and

for the control parameters values not used for mathematical modeling the value stored in the database, obtaining the value by modeling the equipment for the control parameters values.

10. The system of claim 6, wherein intercepting the control parameters further comprises at least one of intercepting the control parameters when the control parameters are entered into a system by an operator and intercepting the control parameters when the control parameters are transmitted to a zone of the actuating elements.

11. A computer program product stored on a non-transitory computer-readable storage medium, the computer program product comprising computer-executable instructions for protecting processing equipment of at least one actuating element by determining whether control parameters for the processing equipment comply with valid control parameters, including instructions for:

modeling a plurality of performance factors of at least one actuating element based on a plurality of sets of the valid control parameters, respectively;

storing, in a database, the modeled performance factors and the plurality of sets of valid control parameters;

intercepting control parameters output from a controller and intended to control the processing equipment of the at least one actuating element before the control parameters are received by the intended processing equipment;

determining whether the intercepted control parameters match any of the valid control parameters stored in the database and, upon a match, accessing a corresponding modeled performance factor for the matched valid control parameters;

accessing, from the database, a predetermined range of values for a permissible performance factor of the at least one actuating element;

comparing the accessed modeled performance factor with the range of values for the permissible performance factor;

if the intercepted control parameters do not match any of the valid control parameters stored in the database, selecting a mathematical model to calculate a predictive performance factor of the least one actuating element based on the intercepted control parameters and comparing the predictive performance factor with the range of values for the permissible performance factor;

preventing the intercepted control parameters from being input to the processing equipment of the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is outside the range of values for the permissible performance factor; and

allowing the intercepted control parameters to be inputted into the processing equipment to control the at least one actuating element when either the modeled performance factor or the calculated predictive performance factor is within the range of values for the permissible performance factor.

12. The computer program product of claim 11, further comprising instructions for:

storing in the database a plurality of values of the calculated predictive performance factor by the selected mathematical model for a plurality of values of the control parameters.

13. The computer program product of claim 11, further comprising calculating of the value of the performance factor comprises synchronous modeling the value for continuous prevention of controlling the at least one actuating element when the calculated performance factor is outside the range of values.

14. The computer program product of claim 13, wherein the synchronous modeling comprises:

for the control parameters values previously used for mathematical modeling the value stored in a database, retrieving the value from the database; and

for the control parameters values not used for mathematical modeling the value stored in the database, obtaining the value by modeling the equipment for the control parameters values.

15. The computer program product of claim 11, wherein intercepting the control parameters further comprises at least one of intercepting the control parameters when the control parameters are entered into a system by an operator and intercepting the control parameters when the control parameters are transmitted to a zone of the actuating elements.