US4907167A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process control system with action logging
Assignee: Rockwell Automation Pavilion Inc
•
Filing: 1987-09-30
•
Granted: 1990-03-06
•
Expires: 2007-09-30
Abstract
Abstract An integrated system for process control in which a process supervisor procedure defines parameters for one or more controller systems (or control procedures). The supervisor procedure changes control parameters only in discrete changes, and the decision to act is sufficiently constrained that every change must be a significant change. Every change is logged (or otherwise reported out to human experts). Since every change is significant, the history of changes will provide a meaningful record which can be reviewed by human experts.
Inventors
- 👤 Richard D. Skeirik
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 03:54
CPC Classifications
G; G05; G05B; G05B13/00; G05B13/02; G05B13/0265; G05B13/028; G06; G06N; G06N5/00; G06N5/04; Y; Y10; Y10S; Y10S706/00; Y10S706/902; Y10S706/903; Y10S706/906; Y10S706/911; Y10S706/914
Claims Analysis
Total Claims: 68
Claim 1
Independent Claim
158 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received from said sensors and in accordance with control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold; and (5) wherein said process supervisor procedure reports every instance where it changes a control parameter.
Claim 2
Dependent Claim
158 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received from said sensors and in accordance with control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold; and (5) wherein said process supervisor procedure reports every instance where it changes a control parameter.
Claim 3
Dependent Claim
28 words
The method of claim 1, wherein said process controller of step (2) uses a cycling step, and said process supervisor procedure of step (3) uses a cycling step.
Claim 4
Dependent Claim
25 words
The method of claim 1, wherein said process supervisor procedure uses a cycling step, and said process controller of step (2) operates in substantially real-time.
Claim 5
Dependent Claim
133 words
The method of claim 1, wherein said process supervisor procedure of step (3) comprises the step of being implemented using a computer running one or more programs, including a cycling process which repeatedly samples a plurality of signals corresponding t inputs, forms inferences from said inputs according to a stored knowledge base, and provides outputs in accordance with said inferences, and then goes into a dormant state having a duration limited by timing; wherein said duration of said dormant state is sufficiently large that said process does not on average occupy more than 50% of the available CPU time of the computer; and wherein said duration of said dormant state is selected to be sufficiently short that process fluctuations cannot diverge to an out-of-control situation during the periods when said process is dormant.
Claim 6
Dependent Claim
33 words
The method of claim 1, wherein said process supervisor procedure of step (3) comprises the step of defining parameters including parameters for a feedback control relation including a deadband on said control parameters.
Claim 7
Dependent Claim
36 words
The method of claim 1, wherein said process supervisor procedure of step (3) comprises the step of having a maximum iteration period significantly longer than the maximum iteration period of said process controller of step (2).
Claim 8
Dependent Claim
17 words
The method of claim 1, wherein said process controller of step (2) uses analog logic for controlling.
Claim 9
Dependent Claim
28 words
The method of claim 1, wherein said step of repeatedly running a process supervisor procedure comprises the step of running said process supervisor procedure using a cycling step.
Claim 10
Dependent Claim
22 words
The method of claim 1, wherein said control parameters of step (2) comprises the step of including goals of said process controller.
Claim 11
Independent Claim
29 words
The method of claim I, wherein said respective threshold on said indicia for action of step (2) comprise the step of being dependent on the particular action in prospect.
Claim 12
Dependent Claim
31 words
The method of claim 1, wherein said respective thresholds on said indicia for action of step (2) comprise the step of being different for at least some of said control parameters.
Claim 13
Dependent Claim
28 words
The method of claim 1, wherein said process controller of step (2) and said process supervisor procedure of step (3) comprise processes running on the safe computer system.
Claim 14
Dependent Claim
29 words
The method of claim 1, wherein said process controller of step (2) and said process supervisor procedure of step (3) are both respective parts of the same software system.
Claim 15
Dependent Claim
122 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuator connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received from said sensors and in accordance with control parameters; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the amount of the change would exceed a certain threshold.
Claim 16
Dependent Claim
122 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuator connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received from said sensors and in accordance with control parameters; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the amount of the change would exceed a certain threshold.
Claim 17
Dependent Claim
28 words
The method of claim 14, wherein said process supervisor procedure of step (3) uses a cycling step, and said process controller of step (2) operates in substantially real-time.
Claim 18
Dependent Claim
33 words
The method of claim 14, wherein said process supervisor procedure of step (3) comprises the step of implementing a feedback control relation including a deadband on at least some of said control parameters.
Claim 19
Dependent Claim
36 words
The method of claim 14, wherein said process supervisor procedure of step (3) comprises the step of having a maximum iteration period significantly longer than the maximum iteration period of said process controller of step (2).
Claim 20
Dependent Claim
14 words
The method of claim 14, wherein said process controller uses analog logic for controlling.
Claim 21
Dependent Claim
22 words
The method of claim 14, wherein said control parameters of step (2) comprise the step of including goals of said process controller.
Claim 22
Dependent Claim
26 words
The method of claim 14, wherein said certain thresholds of step (2) comprise the step of being different for at least some of said control parameters.
Claim 23
Dependent Claim
28 words
The method of claim 14, wherein said process controller of step (2) and said process supervisor procedure of step (3) comprise processes running on the same computer system.
Claim 24
Dependent Claim
29 words
The method of claim 14, wherein said process controller of step (2) and said process supervisor procedure of step (3) are both respective parts of the same software system.
Claim 25
Dependent Claim
142 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received form said sensors and in accordance with control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold.
Claim 26
Dependent Claim
142 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators with a process controller in accordance with signals received form said sensors and in accordance with control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters for said process controller; (4) wherein, for each of said control parameters, said process supervisor procedure is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold.
Claim 27
Dependent Claim
59 words
The method of claim 23, wherein, for each of said control parameters, said process supervisor procedure of step (3) comprises the step of being constrained not to make changes to said control parameters unless the amount of the change would exceed said respective threshold; and wherein said process supervisor procedure reports every instance where it changes a control parameter.
Claim 28
Dependent Claim
44 words
The method of claim 23, wherein, for each of said control parameters, said process supervisor procedure of step (3) comprises the step of being constrained not to make changes to said control parameters unless the amount of the change would exceed said respective threshold.
Claim 29
Dependent Claim
35 words
The method of claim 23, wherein said process supervisor procedure of step (3) comprises the step of implementing at least one feedback control relation including a deadband on at least some of said control parameters.
Claim 30
Dependent Claim
36 words
The method of claim 23, wherein said process supervisor procedure of step (3) comprises the step of having a maximum iteration period significantly longer than the maximum iteration period of said process controller of step (2).
Claim 31
Dependent Claim
17 words
The method of claim 23, wherein said process controller of step (2) uses analog logic for controlling.
Claim 32
Dependent Claim
22 words
The method of claim 23, wherein said control parameters of step (2) comprise the step of including goals of said process controller.
Claim 33
Dependent Claim
31 words
The method of claim 23, wherein said respective thresholds on said indicia for action of step (2) comprise the step of being different for at least some of said control parameters.
Claim 34
Dependent Claim
28 words
The method of claim 23, wherein said process controller of step (2) and said process supervisor procedure of step (3) comprise processes running on the same computer system.
Claim 35
Dependent Claim
29 words
The method of claim 23, wherein said process controller of step (2) and said process supervisor procedure of step (3) are both respective part of the same software system.
Claim 36
Dependent Claim
107 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators in accordance with signals received from said sensors and in accordance with control parameters; (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters; and (4) wherein at least some of said actuators are controlled in a feedforward relation to respective measured variables, and wherein said feedforward relation includes a deadband.
Claim 37
Dependent Claim
107 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; (2) controlling one or more of said actuators in accordance with signals received from said sensors and in accordance with control parameters; (3) repeatedly running a process supervisor procedure for selectively defining one or more of said control parameters; and (4) wherein at least some of said actuators are controlled in a feedforward relation to respective measured variables, and wherein said feedforward relation includes a deadband.
Claim 38
Dependent Claim
25 words
The method of claim 33, wherein said process supervisor procedure of step (3) uses a cycling step, and said step (2) operates in substantially real-time.
Claim 39
Dependent Claim
31 words
The method of claim 33, wherein said process supervisor procedure of step (3) implements at least one feedback control relation including a deadband on at least some of said control parameters.
Claim 40
Dependent Claim
31 words
The method of claim 33, wherein said process supervisor procedure of step (3) has a maximum iteration period significantly longer than the maximum iteration period of said step (2) for controlling.
Claim 41
Dependent Claim
14 words
The method of claim 33, wherein said step (2) uses analog logic for controlling.
Claim 42
Dependent Claim
55 words
The method of claim 33, wherein said control parameters comprise the step of indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action, wherein said respective thresholds on said indicia for action comprise the step of being different for at least some of said control parameters.
Claim 43
Dependent Claim
25 words
The method of claim 33, wherein said respective feedforward relation of step (4) comprises the step of including a deadband applied to a measured variable.
Claim 44
Dependent Claim
27 words
The method of claim 33, wherein said step (2) for controlling and said process supervisor procedure of step (3) comprise processes running on the same computer system.
Claim 45
Dependent Claim
28 words
The method of claim 33, wherein said step (2) for controlling and said process supervisor procedure of step (3) are both respective parts of the same software system.
Claim 46
Dependent Claim
116 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; and (2) controlling one or more of said actuators in accordance with signals received from said sensors; (3) wherein at least some of said actuators are controlled in a feedback relation with respective corresponding measured variables, and said feedback relation includes the use of statistical filtering, and/or a deadband; and (4) wherein at least some of said actuators are controlled in a feedforward relation to respective measured variables, wherein said feedforward relation includes a deadband.
Claim 47
Dependent Claim
116 words
A computer-based method for operating a substantially continuous process, comprising the steps of: (1) operating the process with one or more sensors connected to sense conditions in the process, and one or more actuators connected to change conditions in the process; and (2) controlling one or more of said actuators in accordance with signals received from said sensors; (3) wherein at least some of said actuators are controlled in a feedback relation with respective corresponding measured variables, and said feedback relation includes the use of statistical filtering, and/or a deadband; and (4) wherein at least some of said actuators are controlled in a feedforward relation to respective measured variables, wherein said feedforward relation includes a deadband.
Claim 48
Dependent Claim
30 words
The method of claim 42, further comprising a process supervisor procedure step implementing at least one feedback control relation including a deadband on at least some of said control parameters.
Claim 49
Dependent Claim
30 words
The method of claim 42, further comprising a process supervisor procedure step having a maximum iteration period significantly longer than the maximum iteration period of said step (2) for controlling.
Claim 50
Dependent Claim
14 words
The method of claim 42, wherein said step (2) uses analog logic for controlling.
Claim 51
Dependent Claim
64 words
The method of claim 42, wherein said step (2) further comprises the step of using said control parameters comprise the step of indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action, wherein said respective thresholds on said indicia for action comprise the step of being different for at least some of said control parameters.
Claim 52
Dependent Claim
31 words
The method of claim 42, further comprising process supervisor procedure step, wherein said step (2) or controlling and said process supervisor procedure step comprise processes running on the same computer system.
Claim 53
Dependent Claim
33 words
The method of claim 42, further comprising a process supervisor procedure step, wherein said step (2) for controlling and said process supervisor procedure step are both respective parts of the same software system.
Claim 54
Dependent Claim
131 words
A computer-based process control system, comprising: (a) one or more sensors connected to sense conditions in materials being processed, and one or more actuators connected to change conditions in the process; (b) a plurality of process controllers, each connected to control one or more of said actuators in accordance with signals received from said sensors and in accordance with respective control parameters; and (c) a process supervisor means for selectively defining one or more of said control parameters for said process controllers; (d) wherein, for each of said control parameters, said process supervisor means is constrained not to make changes to said control parameters unless the amount of the change would exceed a certain threshold; and (e) wherein said process supervisor means reports every instance where it changes a control parameter.
Claim 55
Dependent Claim
131 words
A computer-based process control system, comprising: (a) one or more sensors connected to sense conditions in materials being processed, and one or more actuators connected to change conditions in the process; (b) a plurality of process controllers, each connected to control one or more of said actuators in accordance with signals received from said sensors and in accordance with respective control parameters; and (c) a process supervisor means for selectively defining one or more of said control parameters for said process controllers; (d) wherein, for each of said control parameters, said process supervisor means is constrained not to make changes to said control parameters unless the amount of the change would exceed a certain threshold; and (e) wherein said process supervisor means reports every instance where it changes a control parameter.
Claim 56
Dependent Claim
21 words
The system of claim 49, wherein said process supervisor means reports said control parameter change instances by means including voice messaging.
Claim 57
Dependent Claim
28 words
The system of claim 49, wherein said process supervisor means implements at least one feedback control relation including a deadband on at least some of said control parameters.
Claim 58
Dependent Claim
32 words
The system of claim 49, wherein said process supervisor means of element (c) has a maximum iteration period significantly longer than the maximum iteration period of said process controller of element (b).
Claim 59
Dependent Claim
19 words
The system of claim 49, wherein at least one said process controller of eleven (b) is an analog controller.
Claim 60
Dependent Claim
21 words
The system of claim 49, wherein one or more of said control parameters of element (b) goals of said process controller.
Claim 61
Dependent Claim
25 words
The system of claim 49, wherein said certain thresholds of element (d) are different for at least some of said control parameters of element (b).
Claim 62
Dependent Claim
28 words
The system of claim 49, wherein said process controller of element (b) and said process supervisor means of element (c) comprise processes running on the same computer system.
Claim 63
Dependent Claim
29 words
The system of claim 49, wherein said process controller of element (b) and said process supervisor means of element (c) are both respective parts of the same software system.
Claim 64
Dependent Claim
152 words
A computer-based process control system, comprising: (a) one or more sensors connected to sense conditions in materials being processed, and one or more actuators connected to change conditions in the process; (b) a plurality of process controllers, each connected to control one or more of said actuators in accordance with signals received from said sensors and in accordance with respective control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (c) a process supervisor means for selectively defining one or more of said control parameters for said process controllers; (d) wherein, for substantially all of said control parameters said process supervisor means is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold; and (e) wherein said process supervisor means reports every instance where it changes a control parameter.
Claim 65
Dependent Claim
152 words
A computer-based process control system, comprising: (a) one or more sensors connected to sense conditions in materials being processed, and one or more actuators connected to change conditions in the process; (b) a plurality of process controllers, each connected to control one or more of said actuators in accordance with signals received from said sensors and in accordance with respective control parameters, said control parameters indicating a respective threshold, wherein attainment of said threshold as indicated by said signals creates an indicia for action; and (c) a process supervisor means for selectively defining one or more of said control parameters for said process controllers; (d) wherein, for substantially all of said control parameters said process supervisor means is constrained not to make changes to said control parameters unless the indicia for action exceed said respective threshold; and (e) wherein said process supervisor means reports every instance where it changes a control parameter.
Claim 66
Dependent Claim
32 words
The system of claim 58, wherein said process supervisor means of element (c) has a maximum iteration period significantly longer than the maximum iteration period of said process controller of element (b).
Claim 67
Dependent Claim
19 words
The system of claim 58, wherein at least one said process controller of element (b) is an analog controller.
Claim 68
Dependent Claim
30 words
The system of claim 58, wherein said respective thresholds on said indicia for action of element (b) are different for at least some of said control parameters of element (b).
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