Systems and methods for process control including process-initiated workflow

• US 9,594,367 B2
• Filed: 10/31/2011
• Issued: 03/14/2017
• Est. Priority Date: 10/31/2011
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: D'Mura, Paul R., Plache, Kenneth S., Kalan, Michael D., Hall, Kenwood H., Chand, Sujeet
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): Stevens, Thomas
• Application Number:
  US13/285,533
• Publication Number:
  US 20130110274A1
• Time in Patent Office: 1,961 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: G05B 19/05 Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
• CPC Class Codes: G05B 19/41845 characterised by system universality, reconfigurability, modularity
• CPC Class Codes: G05B 2219/32182 If state of tool, product deviates from standard, adjust system, feedback
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A process controller a procedure module that includes instructions for executing a procedure, and a plurality of supplemental procedure modules, each of which includes instructions for executing one of a plurality of supplemental procedures. The process controller also includes a process monitor processor configured to receive an input electronic signal indicative of a status of a process feature, apply logic based on the input electronic signal, and generate an output electronic signal in response to the input electronic signal. The process controller also includes a sequence engine processor configured to execute the procedure, receive the output electronic signal, apply logic based on the output electronic signal, select one or more of the plurality of supplemental procedures based on the received output electronic signal, and execute the selected one or more of the plurality of supplemental procedures.

Claims

1. A process controller, comprising:

memory circuitry, comprising;

a procedure module comprising instructions for executing a procedure,

a plurality of supplemental procedure modules, each of the plurality of supplemental procedure modules comprising instructions for executing one of a plurality of supplemental procedures, and

a production record configured to store data generated from an execution of the procedure module and one or more of the plurality of supplemental procedure modules; and

processing circuitry, comprising;

a process monitor processor configured to receive an input electronic signal indicative of a status of a process feature, apply logic based on the input electronic signal, and generate an output electronic signal in response to the input electronic signal, and

a sequence engine processor configured to execute the procedure module, receive the output electronic signal, apply logic based on the output electronic signal, select one or more of the plurality of supplemental procedure modules based on the received output electronic signal, execute the selected one or more of the plurality of supplemental procedure modules, and update the production record with data generated from the execution of the procedure module and the selected one or more of the plurality of supplemental procedure modules.

2. The system of claim 1, wherein the process monitor processor is configured to compare the input electronic signal to a threshold and generate the output electronic signal if the input electronic signal is outside the threshold and based on a status of a specified criterion associated with the threshold.

3. The system of claim 1, wherein the process feature comprises a procedure step, a piece of equipment, a material, an ingredient, a component, or a combination thereof.

4. The system of claim 1, wherein the sequence engine processor is configured to execute the selected one or more of the plurality of supplemental procedure modules based on a status of a specified criterion associated with the selected one or more of the plurality of supplemental procedure modules.

5. The system of claim 1, wherein the sequence engine processor is configured to execute two or more of the plurality of supplemental procedure modules in parallel.

6. The system of claim 1, wherein the procedure module comprises a sequence of process automation control programs, a sequence of manual instructions, a sequence of software modules, or a combination thereof.

7. The system of claim 1, wherein each of the plurality of supplemental procedure modules comprises a sequence of process automation control programs, a sequence of manual instructions, a sequence of software modules, or a combination thereof.

8. The system of claim 1, wherein each supplemental procedure module of the plurality of supplemental procedure modules is configured to interrupt the execution of the procedure module, replace the procedure module with the supplemental procedure in the memory circuitry, execute in parallel with the procedure module, or a combination thereof.

9. The system of claim 1, wherein the processing circuitry is disposed in a controller, a tablet, a workstation, a cloud-based virtual device, a computing device, or a combination thereof.

10. The system of claim 1, wherein each of the plurality of supplemental procedure modules comprises instructions for exception handling separate from the procedure module.

11. The system of claim 1, wherein the data stored in the production record comprises time values corresponding to when the sequence engine processor executes the procedure module and the selected one or more of the plurality of supplemental procedure modules.

12. The system of claim 1, an operator interface device communicatively coupled to the memory circuitry and the processing circuitry, wherein the operator interface device is configured to provide the input electronic signal to the process monitor processor based on input received from an operator, select the procedure module for execution by the sequence engine processor based on input received from the operator, present the data stored in the production record, or a combination thereof.

13. The system of claim 1, wherein the memory circuitry comprises a scheduling program comprising instructions for the sequence engine processor to begin execution of the procedure module, and wherein the sequence engine processor is configured to execute the scheduling program first.

14. The system of claim 1, wherein the process controller comprises a batch process controller.

15. A program stored on a non-transitory computer readable storage medium, comprising:

computer code disposed on the non-transitory computer readable storage medium, wherein the code comprises instructions for automating a process, the instructions comprising;

instructions for transmitting an input electronic signal indicative of a status of a process feature to a process monitor processor;

instructions for applying logic by the process monitor processor based on the input electronic signal;

instructions for generating an output electronic signal from the process monitor processor in response to the input electronic signal;

instructions for executing a procedure module by a sequence engine processor;

instructions for transmitting the output electronic signal from the process monitor processor to the sequence engine processor;

instructions for applying logic by the sequence engine processor based on the output electronic signal;

instructions for selecting one or more of a plurality of supplemental procedure modules by the sequence engine processor based on the output electronic signal;

instructions for executing the selected one or more of the plurality of supplemental procedure modules by the sequence engine processor; and

instructions for updating a production record with data generated by executing the procedure module and the selected one or more of the plurality of supplemental procedure modules.

16. The program of claim 15, comprising instructions for comparing the input electronic signal to a threshold by the process monitor processor and generating the output electronic signal from the process monitor processor if the input electronic signal is outside the threshold.

17. The program of claim 15, wherein the procedure module or the plurality of supplemental procedure modules comprises a sequence of process automation control programs, a sequence of manual instructions, a sequence of software modules, or a combination thereof.

18. The program of claim 15, wherein each supplemental procedure module of the plurality of supplemental procedure modules is configured to interrupt the procedure module, replace the procedure module with the supplemental procedure module in a memory device, execute in parallel with the procedure module, or a combination thereof.

19. The program of claim 15, wherein the process comprises a batch process.

20. A method for controlling a process with an industrial automation system, comprising:

transmitting an input electronic signal indicative of a status of a process feature to a process monitor processor;

applying logic by the process monitor processor based on the input electronic signal;

generating an output electronic signal from the process monitor processor in response to the input electronic signal;

executing a procedure module by a sequence engine processor;

transmitting the output electronic signal from the process monitor processor to the sequence engine processor;

applying logic by the sequence engine processor based on the output electronic signal;

selecting one or more of a plurality of supplemental procedure modules by the sequence engine processor based on the output electronic signal;

executing the selected one or more of the plurality of supplemental procedure modules by the sequence engine processor; and

updating a production record with data generated by executing the procedure module and the selected one or more of the plurality of supplemental procedure modules.

21. The method of claim 20, comprising executing two or more of the plurality of supplemental procedure modules in parallel by the sequence engine processor.

22. The method of claim 20, comprising executing a scheduling program by the sequence engine processor, wherein the scheduling program instructs the sequence engine processor to execute the procedure module.

23. The method of claim 20, wherein the process comprises a batch process.