Patent Application
20100082145
The subject innovation relates generally to industrial automation design, and more particularly to industrial controller based systems and/or methodologies for defining and/or implementing one or more routes from a source to a destination.
Industrial controllers are special-purpose computers utilized for controlling industrial processes, manufacturing equipment, and other factory automation, such as data collection or networked systems. At the core of the industrial control system, is a logic processor such as a Programmable Logic Controller (PLC) or PC-based controller. Programmable Logic Controllers for instance, are programmed by systems designers to operate manufacturing processes via user-designed logic programs or user programs. The user programs are stored in memory and generally executed by the PLC in a sequential manner although instruction jumping, looping and interrupt routines, for example, are also common. Associated with the user program are a plurality of memory elements or variables that provide dynamics to PLC operations and programs. Differences in PLCs are typically dependent on the number of Input/Output (I/O) they can process, amount of memory, number and type of instructions, and speed of the PLC central processing unit (CPU).
One area that has Seen significant growth in recent years is route management in industrial applications. Route management includes the movement of materials from a set of source storage containers through a limited set of intermediary containers (e.g., pipes, conveyers) to a set of destination containers or equipment (fillers). Typically, route management is accomplished by hard coding or manual entering of all possible combinations and permutations of routes into a controlling software along with a human machine interface.
Hard coding and manually entering all possible combinations and permutations of routes into a controlling software can be extremely inefficient. For example, troubleshooting or upgrading equipment can often require massive amounts of re-engineering. Therefore, it would be desirable to have an efficient and convenient routing management solution.
The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed embodiments. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such embodiments. Its purpose is to present some concepts of the described embodiments in a simplified form as a prelude to the more detailed description that is presented later.
The claimed subject matter relates to a system and/or method for convenient and efficient programmable logic controller based route determinations. In accordance with various aspects of the claimed subject matter an industrial controller controls at least one device within a set of paths and/or obtains data from at least one device within a set of paths, and a routing component that determines at least one route from a destination to a source within the paths.
In additional aspects, a method facilitating routing management is disclosed, the method includes storing a set of routing data in a memory, wherein the routing data defines one or more routes from a source to a destination, translating the routing data into a set of industrial controller executable commands, and implementing the route by controlling at least one device along the route via the industrial controller.
In still other aspects, a routing management method is disclosed, that includes a programmable controller that executes the steps of: determining at least one source for at least one ingredient in a product, and at least one destination for at least one of a bi-product of manufacture based on the ingredients, or the ingredients, and calculating at least one route from the source to the destination.
To the accomplishment of the foregoing and related ends, one or more embodiments comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects and are indicative of but a few of the various ways in which the principles of the embodiments may be employed. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings and the disclosed embodiments are intended to include all such aspects and their equivalents.
The subject matter is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject matter. It may be evident, however, that subject matter embodiments may be practiced without these specific details. In other instances, well-known structures and devices are illustrated in block diagram form in order to facilitate describing the embodiments.
As used in this application, the terms “component,” “system,” “object,” “model,” “policy,” and the like are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers. Also, these components can execute from various computer readable media having various data structures stored thereon. The components may communicate via local and/or remote processes such as in accordance with a signal having one or more data packets (e.g., data from one component interacting with another component in a local system, distributed system, and/or across a network such as the Internet with other systems via the signal).
As used herein, the term “inference” refers generally to the process of reasoning about or inferring states of the system, environment, and/or user from a set of observations as captured via events and/or data. Inference can be employed to identify a specific context or action, or can generate a probability distribution over states, for example. The inference can be probabilistic—that is, the computation of a probability distribution over states of interest based on a consideration of data and events. Inference can also refer to techniques employed for composing higher-level events from a set of events and/or data. Such inference results in the construction of new events or actions from a set of observed events and/or stored event data, whether or not the events are correlated in close temporal proximity, and whether the events and data come from one or several event and data sources. Furthermore, inference can be based upon logical models or rules, whereby relationships between components or data are determined by an analysis of the data and drawing conclusions therefrom. For instance, by observing that one user interacts with a subset of other users over a network, it may be determined or inferred that this subset of users belongs to a desired social network of interest for the one user as opposed to a plurality of other users who are never or rarely interacted with.
Referring initially to
In addition, the interface component 104 enables the industrial controller 102 to communicate with one or more devices 108. The devices 108 can include most any of a plurality of industrial control devices, including but not limited a motor 108a, a valve 108b, a sensor 108c, an indicator 108d, a pump 108e, and so forth. In operation, the industrial controller 102 can communicate instructions to one or more of the devices 108 and/or obtain data, measurements, or information from the devices 108. For instance, the devices 108 can include a temperature sensor, wherein the industrial controller 102 can obtain a current/voltage signal that corresponds to a temperature measurement from the temperature sensor.
The routing component 106 provides for an industrial controller 102 based solution enabling static and/or dynamic routing from one or more sources to one or more destinations. The routing component 106 enables static routing by interpreting data (e.g. a table) that defines a specific route from a source to a destination. The route can be defined as one or more means of conveying (e.g. conduit, channel, conveyor, pipes, etc.) one or more materials (e.g. liquid, gas, solids, etc.) from a starting point to a target location (See
The routing component 106 supports multiple states, including but not limited to starting, running, stopping, holding, restarting, aborting, and so forth. For each state, the routing component 106 can enable a separate sequence of devices 108. The state sequence can allow inclusion of most any device 108 assigned to a route. Additionally or alternatively, devices 108 which are not included within a particular state can remain in their existing state. For instance, the routing component 106 can have the ability to close select valves in the holding state.
The routing component 106 can support multiple steps within a given state, wherein the steps enable the routing component 106 to sequence devices. On each step one or many devices 108 may be sequenced. For example, a routing component 106 interface can include: Abort command, Aborted Status; Hold Command, Held Status; Starting Status; Restart Command, Restarting Status. In addition, the routing component 106 can enable monitoring the state of most any devices 108 which are not controlled within a given route. Moreover, the routing component 106 enables configuration of devices 108 to pulse, and the ability to assign one or more pulse sequences, and number of pulses for each device 108, and the ability to loop the sequences for a predefined number of loops. For example, the routing component 106 can monitor a number of times the sequences have been completed.
The routing component 106 can include a policy component 110. The policy component 110 can contain one or more policies, wherein the routing component 106 can determine the route(s) based at least in part on the policies. For instance, the policies can include one or more business rules that affect the possible routes. Consequently, the routing component 106 will determine one or more routes that follow or do not violate the business rules. Additionally or alternatively, the policies component 110 can contain one or more sets of material compatibility rules. The material compatibility rules can be used by the routing component 106 to determine one or more possible routes as well (discussed infra).
The policy component 110 can obtain the policies from most any of a plurality of sources. For instance, the policies can be acquired via the interface component 104 from a data store (not shown), an external source, user input, and so forth. It is to be appreciated that this is but one example, and multiple embodiments are possible within the scope and spirit of the subject innovation.
Turning to
The routing component 202 includes a recipe component 204, a material track (m-track) component 206, a material based phase component 208, an equipment component 210, an interlocks component 212, and a policies component 214. The recipe component 204 can receive, acquire, or otherwise obtain one or more recipes. The recipes define a set of products to be delivered. For example, the recipe component 204 can obtain a recipe for a product Z, wherein the recipe for Z contains 0.25 of an ingredient W, 0.25 of an ingredient X, and 0.5 of an ingredient Y.
The material track component 206 determines one or more sources to use for the recipe based on a set of container priorities. The container priorities maintain a priority level for one or more containers. Returning to the previous example, there can be a plurality of containers having the ingredient W. The priority levels maintained in the container priorities can determine the order in which the containers should be used as a source for the ingredient W. The material based phase component 208 determines one or more routes required to implement the recipe using the container priorities. Again reverting to the previous example, in order to manufacture the product Z using the ingredients W, X, and Y several steps may be involved. The material based phase component 208 can determine routes possible for the steps. For instance, manufacturing the product Z can require a first step of heating the ingredient W and a second step of cooling the ingredient W. The material based phase component 208 can determine the routes that incorporate a heater for the first step, and a refrigerator for the second step. It is to be appreciated that this is but one example, and a plurality of routes and steps are possible within the scope and spirit of the subject innovation.
The equipment component 210 can determine one or more pieces of equipment to be used, and request control of the equipment. Staying with the previous example, the equipment component 210 determines that the heater and refrigerator are associated with the route, and requests control of the heater and refrigerator for use by the routing component 202. The interlocks component 212 can determine undesired states for the equipment associated with route, and implement one or more instructions that prevent the equipment from entering the undesired state(s). For example, the interlocks component 212 can determine the undesirable states based at least in part on a set of material compatibility rules and/or business rules (discussed infra), and implement a set of instructions to prevent the equipment from entering a state that conflicts with the material compatibility and/or business rules.
As previously discussed, the policies component 214 can contain one or more policies, that can impact, influence, or otherwise affect the routes determined by the routing component 202. The policies component 214 includes a set of material compatibility rules 216 and a set of business rules 218. The material compatibility rules 216 contain regulations regarding the ability to mix, blend, or otherwise combine two or more materials. For example, the material compatibility rules 216 can state that the ingredient W and the ingredient Y may not be able to mix until a final stage of production. Consequently, W may not be able to traverse any conduits that have previously been traversed by Y and/or vice/versa. As an additional example, the business rules 218 can contain a set of rules regarding the quality of the ingredient Y to be used in the manufacture of the product Z, which impacts the container priorities determined by the M-track component 206. It is to be appreciated that the routing component 202 is illustrated for simplicity and brevity of explanation; however a plurality of possible embodiments of routing components are possible within the scope and spirit of the subject innovation.
The example path 300 is illustrated as a three by three matrix having nine matrix valves 302 and twelve channels 304. The path has a source 306 and a destination 308. For example, the source 306 and the destination 308 can be determined by a routing component based on a recipe and/or routing instructions (discussed supra). It can be Seen that a plurality of routes are possible using various combinations of matrix valves 302 and channels 304 from the source 306 to the destination 308. Without traversing any of the matrix valves 302 or channels 304 more than once there are six possible routes 310-320 from the source 306 to the destination 308.
As discussed previously, the industrial controller based routing component can dynamically determine the routes within the path 300 based at least in part on a set of business rules, a set of material compatibility rules, and/or real-time monitoring of devices such as the matrix valves 302 and channels 304. For example, if the matrix valve in the bottom right corner of the path 300 is inoperable then the route 310 will not be used by the routing component. Additionally or alternatively, the routing component can determine that each of the routes 310-320 is possible and a user may select their preferred route. It is to be appreciated that this is but one example illustrated for simplicity of explanation and brevity, and that most any number and type of devices, channels, valves, and so forth can comprise a path within the scope and spirit of the subject innovation.
As previously discussed, each possible route is not necessarily reflective of a best or even a practical route. A number of routes can be eliminated based on one or more policies. For instance, continuing with the example discussed supra, the conduit 404 leading to the valve 408a may not be useable based on one or more material compatibility rules. In addition, the conduit 404 may not be practical based on one or more business rules. Moreover, the conduit 404 leading to the valve 408c may not be operable due to a failure. Therefore, the best possible route from the valve 408d to the destination 406 may involve using the conduit 404 leading to the valve 408b.
It is to be appreciated that it would be desirable to have a controller based system and/or methodology that can determine one or more routes through the paths 400, while accounting for a set of policies and/or real time monitoring of the devices located along or in the paths 400.
The table is illustrated as having 1-n downstream materials 504 and upstream materials 502, where n is an integer. The first example material (e.g., product 1) represents a clean pipe, and the second example material (e.g., product 2) represents one or more clean in-place (CIP) cleaning solutions. The third through the sixth materials (e.g., product 3-6) are dark materials and the seventh through the tenth materials (e.g., product 7-10) are light materials.
The two dimensional array illustrated in the table 500 contains editable fields that define if the materials are compatible (e.g., Y) or not compatible (e.g., N). For example, the table as illustrated shows that all the materials (products 2-n) can flow into a clean pipe (e.g., row 1). However, none of the materials are allowed to flow into the cleaning solutions (e.g., row 2). In addition, the dark materials can flow into a light material, but light materials cannot flow into a dark material, as illustrated by row 4 column 9, and row 9 column 4.
As previously discussed, a routing component (See
In view of the example systems described supra, methodologies that may be implemented in accordance with the disclosed subject matter will be better appreciated with reference to the flow charts of
With reference to
At 604, the routing data is interpreted, converted, or otherwise translated into a set of instructions that can be used to direct one or more articles along the specified route. For instance, a series of valves may need to be controlled in order to implement the specified route, and the routing data can be translated into a set of instructions effective to control the necessary valves. At 606, the route contained in the routing table is implemented by controlling the necessary devices using the set of instructions interpreted from the routing table.
At 608, the statuses of the devices within the defined path are monitored in real-time. The devices can be monitored to confirm information, such as a state (e.g. open/close, on/off, etc.), a mode (auto, manual, etc.), a health indicator (in alarm, out of alarm, in service, not in service, etc.), a material compatibility (e.g. do the business rules allow mixing of two or more materials?), and so forth. The status of the devices can be returned to a user via an indicator (display, etc.), or the route can be altered based on the device status.
At 706, a determination is made as to whether the current valve is the destination. It is to be appreciated, that most any of a plurality of industrial devices can be the destination, including but not limited to a motor, a valve, a pump, a relay, an indicator, and so forth. At 708, if the valve is the destination, then the path is completed. At 710, if the valve is not the destination, then the current device's neighbors are located.
At 712, once the neighbors are located a new context call can be generated, and the method returns to 702 to find the next path. It is to be appreciated that this is but one example of a methodology facilitating dynamic routing, and a plurality of methods are possible within the scope and spirit of the subject innovation. In addition, it is to be appreciated that the aforementioned methodology for dynamic routing can be used in conjunction with the methodology presented in
Referring to
At 804, one or more container priorities can be determined for the ingredients contained in the recipes. The container priorities specify a source for the ingredients. As discussed supra, the ingredients can have a plurality of possible sources, and the container priorities can detail the order in which those sources are to be used. At 806, one or more routes can be determined (See
At 810, the route is implemented. Implementation of the route can involve acquiring control of devices associated with the route, and controlling the devices. For example, a series of valves along the route can be required for implementation of the route. In addition, the route devices associated with the route are monitored in real-time for a plurality of factors, such as health. The route can be automatically updated or indications can be displayed, sent, or otherwise communicated to a user. It is to be appreciated that this is but one example, and a plurality of route management techniques are possible within the scope and spirit of the subject innovation.
Referring to
The modules 14 within the rack 12A may include, for example, a power supply module 18, a processor module 26, two communication modules 24A and 24B and two I/O modules 20. A power supply module 18 receives an external source of power (not shown) and provides regulated voltages to the other modules 14 by means of conductors on the backplane 16A.
The I/O modules 20 provide an interface between inputs from, and outputs to external equipment (not shown) via cabling 22 attached to the I/O modules 20 at terminals on their front panels. The I/O modules 20 convert input signals on the cables 22 into digital words for transmission on the backplane 16A. The I/O modules 20 also convert other digital words from the backplane 16A to the necessary signal levels for control of equipment.
The communication modules 24A and 24B provide a similar interface between the backplane 16A and one of two external high speed communication networks 27A and 27B. The high speed communication networks 27A and 27B may connect with other modules 14 or with remote racks of I/O modules 20 or the like. In the example illustrated, the high speed communication network 27A connects with backplane 16A via the communication module 24A, whereas the high speed communication network 27B connects the communication module 24B with communication modules 24C and 24D in rack 12B.
The processor module 26 processes information provided by the communication modules 24A and 24B and the I/O modules 20 according to a stored program and provides output information to the communication module 24 and the I/O modules 20 in response to that stored program and received input messages.
Referring also to
Local communication with the other modules 14 through the backplane 16 is accomplished by means of a backplane interface 32 which electrically connects the backplane 16 through connector 30. The backplane interface 32 monitors messages on the backplane 16 to identify those messages intended for the particular module 14, based on a message address being part of the message and indicating the message's destination. Messages received by the backplane interface 32 are conveyed to an internal bus 34 in the module 14.
The internal bus 34 joins the backplane interface 32 with a memory 36, a microprocessor 28, front panel circuitry 38, I/O interface circuitry 39 (if the module is an I/O module 20) and communication network interface circuitry 41 (if the module is a communication module 24). The microprocessor 28 may be a general purpose microprocessor providing for the sequential execution of instructions contained in memory 36 and the reading and writing of data to and from the memory 36 and the other devices associated with the internal bus 34.
The microprocessor 28 includes an internal clock circuit (not shown) providing the timing of the microprocessor 28 but may also communicate with an external precision clock 43 of improved precision. This clock 43 may be a crystal controlled oscillator or other time standard including a radio link to an NBS time standard. The precision of the clock 43 is recorded in the memory 36 as a quality factor. The panel circuitry 38 includes status indication lights such as are well known in the art and manually operable switches such as for locking the module 14 in the off state.
The memory 36 holds programs executed by the microprocessor 28 to provide the functions as will be described and also variables and data necessary for the execution of those programs. For I/O modules 20, the memory 36 also includes an I/O table holding the current state of inputs and outputs received from and transmitted to the industrial controller 10 via the I/O modules 20.
A classifier is a function that maps an input attribute vector, x=(x1, x2, x3, x4, xn), to a confidence that the input belongs to a class, that is, f(x)=confidence(class). Such classification can employ a probabilistic and/or statistical-based analysis (e.g., factoring into the analysis utilities and costs) to prognose or infer an action that a user desires to be automatically performed.
A support vector machine (SVM) is an example of a classifier that can be employed. The SVM operates by finding a hypersurface in the space of possible inputs, which hypersurface attempts to split the triggering criteria from the non-triggering events. Intuitively, this makes the classification correct for testing data that is near, but not identical to training data. Other directed and undirected model classification approaches include, e.g., naïve Bayes, Bayesian networks, decision trees, neural networks, fuzzy logic models, and probabilistic classification models providing different patterns of independence can be employed. Classification as used herein also is inclusive of statistical regression that is utilized to develop models of priority.
As will be readily appreciated from the subject specification, the subject innovation can employ classifiers that are explicitly trained (e.g., via a generic training data) as well as implicitly trained (e.g., via observing user behavior, receiving extrinsic information). For example, SVM's are configured via a learning or training phase within a classifier constructor and feature selection module. Thus, the classifier(s) can be used to automatically learn and perform a number of functions, including but not limited to determining according to a predetermined criteria when to update or refine the previously inferred schema, tighten the criteria on the inferring algorithm based upon the kind of data being processed (e.g., financial versus non-financial, personal versus non-personal, . . . ), and at what time of day to implement tighter criteria controls (e.g., in the evening when system performance would be less impacted).
Referring now to
The system 1200 also includes one or more server(s) 1204. The server(s) 1204 can also be hardware and/or software (e.g., threads, processes, computing devices). The servers 1204 can house threads to perform transformations by employing the innovation, for example. One possible communication between a client 1202 and a server 1204 can be in the form of a data packet adapted to be transmitted between two or more computer processes. The data packet may include a cookie and/or associated contextual information, for example. The system 1200 includes a communication framework 1206 (e.g., a global communication network such as the Internet) that can be employed to facilitate communications between the client(s) 1202 and the server(s) 1204.
Communications can be facilitated via a wired (including optical fiber) and/or wireless technology. The client(s) 1202 are operatively connected to one or more client data store(s) 1208 that can be employed to store information local to the client(s) 1202 (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) 1204 are operatively connected to one or more server data store(s) 1210 that can be employed to store information local to the servers 1204.
What has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
This application claims priority to U.S. Provisional Application Ser. No. 61/101,238, filed Sep. 30, 2008, entitled “ROUTING MANAGER”, the entirety of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61101238 | Sep 2008 | US |
