Methods and systems for batch processing and execution in a process system

• US 9,804,589 B2
• Filed: 09/23/2011
• Issued: 10/31/2017
• Est. Priority Date: 05/15/2007
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Pettus, Nathan, Irwin, Will, Conner, Kim, Nanda, Mickey
• Primary Examiner(s): Everett, Christopher E
• Application Number:
  US13/243,713
• Publication Number:
  US 20120016494A1
• Time in Patent Office: 2,230 Days
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 19/41845 characterised by system universality, reconfigurability, modularity
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32077 Batch control system
• CPC Class Codes: G05B 2219/32096 Batch, recipe configuration for flexible batch control
• CPC Class Codes: G05B 2219/32098 Batch programming using oop
• CPC Class Codes: G05B 2219/32161 Object oriented control, programming
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• 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 for implementing a control process within a process control system and resolving inconsistencies during execution of the control process includes loading the logical structure of the control process, loading a plurality of instantiation objects or processes when the control process is instantiated, using the instantiation objects to instantiate a procedural element of the control process as the control process calls for the procedural element during execution, executing the procedural element as part of the control process, and deconstructing the procedural element as execution of the procedural element is completed during execution of the control process. Resolution of inconsistencies includes executing a first model of an entity in a controller, executing a second model of the entity in an execution engine, detecting a difference between the models, generating a prompt and receiving an operation instruction to continue the process or abort the process.

Claims

1. A system for resolving inconsistencies in device models within a process control system while executing a batch process, the system comprising:

a process controller having a first physical model of an equipment entity, wherein the process controller is adapted to control the equipment entity and wherein the first physical model of the equipment entity describes the equipment entity within the process control system;

a batch process execution engine having a second physical model of the equipment entity, wherein the batch process execution engine is adapted to provide a control instruction to the process controller based on the second physical model of the equipment entity, wherein the process controller is adapted to execute the control instruction based on the first physical model of the equipment entity, and wherein the second physical model of the equipment entity describes the equipment entity within the process control system; and

a control execution object that detects a difference between the first and second physical models of the equipment entity during execution of the batch process and generates a prompt in response to the detection of the difference during execution of the batch process, and receives an operation instruction in response to the prompt regarding continued operation of the batch process during execution of the batch process, wherein the operation instruction comprises one of continuing execution of the batch process without interruption of the execution of the batch process or aborting execution of the batch process.

2. The system of claim 1, wherein the prompt comprises an identification of the difference between the first and second physical models of the equipment entity.

3. The system of claim 1, wherein the prompt comprises a display of the difference between the first and second physical models of the equipment entity to a user.

4. The system of claim 1, wherein the operation instruction comprises an operation instruction from the batch process to continue execution of the batch process.

5. The system of claim 1, wherein the operation instruction comprises an operation instruction from a user, wherein the user is provided with the option between continuing execution of the batch process and aborting execution of the batch process.

6. The system of claim 1, further comprising a plurality of process controllers, wherein the difference between the first and second physical models of the equipment entity comprises a difference in a parameter of the first and second physical models of the equipment entity, wherein the operation instruction comprises an operation instruction to continue execution of the batch process using a universal parameter, the universal parameter being provided to each of the plurality of process controllers that utilizes the parameter.

7. The system of claim 1, wherein the difference between the first and second physical models of the equipment entity comprises a difference in a parameter of the first and second physical models of the equipment entity, and wherein the operation instruction comprises an operation instruction to continue execution of the batch process using a default parameter.

8. The system of claim 1, wherein the difference between the first and second physical models of the equipment entity comprises a difference in a parameter of the first and second physical models of the equipment entity, and wherein the operation instruction comprises an operation instruction to continue execution of the batch process using a previous parameter used by the first and second physical models.

9. A method of resolving inconsistencies in a processing and execution environment comprising:

executing a batch process based on a first version of a physical model of an equipment entity to generate control parameters, wherein the first version of the physical model of the equipment entity describes the equipment entity within the process control system;

transmitting control parameters to a controller in the process, wherein the controller is adapted to control the entity;

executing a control function using the control parameters with a second version of the physical model of the equipment entity, wherein the second version of the physical model of the equipment entity describes the equipment entity within the process control system;

in response to detecting a difference between the first and second versions of the physical model of the equipment entity, requesting an operation instruction during execution of the batch process regarding continued operation of the batch process based on the ability of the second version of the physical model of the equipment entity to use the control parameters, wherein the second version of the physical model of the equipment entity generates an error if the parameters are not usable with the second version of the physical model of the equipment entity;

continuing execution of the batch process without interruption of the execution of the batch process if the operation instruction comprises a continue execution instruction; and

aborting execution of the batch process if the operation instruction comprises an abort execution instruction.

10. The method of claim 9, wherein requesting an operation instruction comprises communicating a prompt having an identification of the difference between the first and second versions of the physical models of the equipment entity.

11. The method of claim 9, wherein requesting an operation instruction comprises displaying of the difference between the first and second versions of the physical models of the equipment entity to a user.

12. The method of claim 9, further comprising:

generating the error if the parameter is not usable due to a difference in a parameter of the first and second versions of the physical model; and

providing a universal parameter to each of a plurality of controllers that utilize the parameter,

wherein continuing execution of the batch process comprises continuing execution of the batch process using the universal parameter.

13. The method of claim 9, further comprising generating the error if the parameter is not usable due to a difference in a parameter of the first and second versions of the physical model, wherein continuing execution of the batch process comprises continuing execution of the batch process using a default parameter.

14. The method of claim 9, further comprising generating the error if the parameter is not usable due to a difference in a parameter of the first and second versions of the physical model, wherein continuing execution of the batch process comprises continuing execution of the batch process using a previous parameter used by the first and second versions of the physical model.