WO1997045778A1 - Real-time process control simulation method and apparatus - Google Patents
Real-time process control simulation method and apparatus Download PDFInfo
- Publication number
- WO1997045778A1 WO1997045778A1 PCT/US1997/007461 US9707461W WO9745778A1 WO 1997045778 A1 WO1997045778 A1 WO 1997045778A1 US 9707461 W US9707461 W US 9707461W WO 9745778 A1 WO9745778 A1 WO 9745778A1
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- Prior art keywords
- operating system
- real
- software
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- control
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- 238000004088 simulation Methods 0.000 title claims description 47
- 238000004886 process control Methods 0.000 title claims description 4
- 238000000034 method Methods 0.000 title description 19
- 238000004891 communication Methods 0.000 claims description 44
- 238000013461 design Methods 0.000 abstract description 8
- 238000012360 testing method Methods 0.000 abstract description 6
- 238000012549 training Methods 0.000 abstract description 4
- 230000008569 process Effects 0.000 description 9
- 230000006870 function Effects 0.000 description 5
- 238000011161 development Methods 0.000 description 4
- 230000006399 behavior Effects 0.000 description 3
- 230000003278 mimic effect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 238000011017 operating method Methods 0.000 description 2
- 238000004590 computer program Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000010076 replication Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B17/00—Systems involving the use of models or simulators of said systems
- G05B17/02—Systems involving the use of models or simulators of said systems electric
Definitions
- the invention relates in general to the field of industrial control and, more particularly, to a method and apparatus for running control software developed to run on a process controller having a proprietary real-time operating system within a non-proprietary operating system such that the control software may be tested and modified in a non-real-time environment.
- a typical industrial control system 100 comprises a plant 105, at least one device controller 110, a man-machine interface (MMI) unit 115, and a proprietary communication network 120 that links the control system's different elements.
- MMI man-machine interface
- a proprietary communication network 120 that links the control system's different elements.
- the plant 105 consists of the actual machinery and/or devices that constitute the industrial system being monitored and controlled.
- the device controller 110 is a combination of control software 125 running within a proprietary real-time tied operating system and hardware 130 elements which, together, implement the control of a plant device or machine.
- the MMI 115 provides an operator interface through which the plant conditions and, in particular, the device controller 110 can be monitored and/or controlled.
- an operational plant 105 will typically comprise a large number of different devices (machines) and that many of these devices will have their own device controller. It will further be understood that a device controller's 110 software 125 and hardware 130 elements are designed to monitor and control a
- a device controller's software 125 element is designed to monitor and control a specific machine via its hardware 130 element, the device controller is limited to two operational modes: off and real-time.
- a typical plant simulation system 200 comprises a plant model (PM) 205, at least one device controller simulator 210, a man-machine interface (MMI) unit 215, and a communication network that links the simulation system's different elements.
- the plant model 205 is typically a software application designed to mimic the process/plant under study and is available from
- the device controller simulator 210 is a software application that is designed to simulate both the device controller's software element 125 and its hardware element 130.
- the actual control software that would actually run on the device controller is not used in such simulation environments, but rather a program developed to mimic key performance aspects of the actual control software.
- the simulation system's MMI 215 serves an analogous function as does the MMI 115 in an operational plant, that is, to monitor and control plant simulation.
- control parameters 225 from the simulation system's MMI 215 to a device controller 110. (This latter feature must account
- the device controller simulator 210 comprises a software design engineer's "best guess" replication of the control device's operational characteristics and environment. That is, the device controller simulator 210 is comprised of
- the device controller simulator 210 only roughly approximates the behavior of the actual device controller 110; the device controller simulator 210
- a method and apparatus in accordance with the invention overcomes the fidelity problems associated with device control simulators by using, in a non-
- the invention provides an API (application program interface) to exercise the control algorithm program code.
- the API is designed to allow the actual device controller software to operate in a non-proprietary communication's environment while also providing the capability to arbitrarily stop and start the controller software's operation, exercise the controller software at a rate slower and faster than real-time, restore the controller software to a known state, and store the configuration of the software controller
- the invention provides a very high fidelity simulation of a control device while avoiding the need for users to design/engineer around their current control system's proprietary communication's network or data highway.
- fidelity provided by the invention allows an operator to design, test, and verify control system strategies in a more comprehensive manner than possible in prior art systems.
- An added benefit of the invention is that it can be used as an improved operator training system.
- Figure 1 shows a simplified schematic diagram of a prior art industrial
- Figure 2 shows a simplified schematic diagram of a prior art industrial control plant simulation system.
- Figure 3 shows a simplified schematic of an industrial control plant emulation system in accordance with the invention.
- an industrial control system 300 in accordance with the invention is comprised of a process model (PM) 205, a simulation engineering environment unit 305, a MMI (man-machine interface) unit 355, and a non-
- the simulation unit 305 is comprised of controller software 320, an API (application
- program interface 325
- means to process I/O (input/output) 330 to and from the simulation unit a communications server 335, and a communications application 340.
- the simulation unit 305 may be housed in a single VME chassis which provides backplane communication between each of the unit's functional elements, 320 through 340 which can be implemented on VME cards.
- an illustrative simulation unit 305 executes under a standard operating system (such as, for example, "UNIX,” “WINDOWS NT, " or "Open VMS”) to provide a standard operating system.
- a simulation unit 305 in accordance with the invention could also contain one or more storage means such as, for example, magnetic hard disks,
- Such tape drives may be used to allow the simulation unit 305 to read/ write "configuration tapes" readable by the control software 320, that contain configuration data used by the control software 320 to implement various control processess.
- each simulation unit 305 may also comprise an operator console including a video display, keyboard, and a suitable input/output device.
- simulation unit's 305 other elements (controller software 320, API 325, communication's server 335, and communication's application 340 will be described in more detail below.
- Plant model 205 can be either a stand-alone element or incorporated within
- the simulation unit's controller software 320 is a direct port of a device controller's 110 software control algorithms/program code 125 so that it executes in a non-proprietary operating system such as, for example, "UNIX” or "VMS. "
- a non-proprietary operating system such as, for example, "UNIX” or "VMS.
- controller software 320 is a direct port of the actual device controller software 125 it is not a simulation or emulation - the controller software 320 responds to data
- the software comprises a rehosted version of the PROVOX process management software available from Fisher-Rosemount Systems, Inc. , the assignee of the present invention.
- the ported control software could comprise ported versions of: the SRx controller software; operator workplace console software to provide a graphical interface for the user; configuration software for configuring the various control devices; shared memory applications; external I/O interface software; a highway data link server; and an API library for software manipulation applications.
- process management software e.g. , the RS3 software available from the assignee of the present invention, are rehosted on to the simulation unit 305.
- Standard porting and re-hosting techniques may be used to rehost the control software from the real-time tied operating system to the non-real-time tied, non -proprietary operating system running on simulation unit 305.
- Such techniques may involve the creation of software "layers" that surround the re-hosted control software and act as intermediaries between the re-hosted software and the non- proprietary, non-real-time tied operating system running on the simulation unit.
- the precise form and number of layers that may be required to accomplish the port will depend on the nature of the original control software and on the specific non-proprietary, non-real-time tied operating system running on simulation unit 305.
- One of ordinary skill in the art having the benefit of this disclosure should be able to port original control software to a non-proprietary operating system without undue experimentation.
- the API 325 is a function library that allows manipulation of the controller software algorithms 320, including: (1) freeze/unfreeze (e.g. , start/stop) capability, (2) store/restore capability, (3) fast/ slow execution capability, relative to real-time (e.g. , V4 time, V ⁇ time, 2X time 3X time, 4X time, and 5X time), and (4) the insertion/retrieval of controller values such as setpont, pv, and controller tuning constraints.
- the API 325 is used to communicate with the controller software 320 in the same manner as prior art systems communicate (i.e. , pass information) with control device simulators 210.
- controller software 320 - API 325 combination provides an operator with the capability to exercise an actual control device's software algorithms in non-real-time and in a platform (computer system)
- control software algorithms 320 are functionally identical to those run in the actual control plant (i.e. , 125).
- an operator can, with very high fidelity, verify plant operating procedures, test new
- the API 325 also provides a set of function calls by which the MMI 355 communicates with the simulation unit 305 as well as function calls to allow the communication server 335 to interact with both the system's non-proprietary network 310 and the real-time proprietary data highway 120. Both the MMI 355 and communication server 335 is discussed in more detail below.
- the communication server 335 provides a means for two-way communication between the simulation unit 305 and the industrial plant's 105 data highway 120. Because each vendor's data highway network is proprietary, the precise implementation of this element will depend upon the type of control network being used.
- the communication server 335 provides functions such as the capability to receive, process, and transmit messages for the purposes of establishing, verifying, and releasing one or more communication ports (e.g., TCP/IP sockets) between the non-proprietary 310 and proprietary 120 computer networks. Self-testing capability is another common feature of cross-network communication servers.
- One benefit of the communication server 335 is the ability to provide the plant model (PM) 205 and the controller software 320 with real-time information about the operational plant's 105 behavior. This data can be used to compare, update, and correct the PM's 205 operation. Additionally, plant configuration data
- the communication server 335 can be used to transfer configuration and control information from the
- simulation unit 305 to an operational control plant's 105 device controller 110.
- a control routine or process may be developed and refined through the use of the simulation unit 305 and then downloaded to the controller 110. This potentially minimizes the downtime normally associated with such development and may reduce the potential for introducing errors into an operational industrial
- the communication application 340 provides a means for each of the individual components of the simulation unit 305 to communicate with one another
- all communication is in binary file format utilizing big endian/little endian byte swapping, and all data is handled in I.E.E.E. floating point format.
- the communication's application 340 is implemented as a shared memory application.
- the MMI 355 reads and writes to the shared memory application which is then responsible for notifying the other simulation unit 305 elements that new data and/or commands
- each of the other simulation unit 305 elements can be designed to periodically query or inspect the status of the communication's application 340. Further, it is via the communication's application 340 that information is transferred between the simulation unit's 305 individual elements on the VME backplane.
- MMI Unit MMI Unit
- a MMI unit 355 in accordance with the invention is essentially the same as prior art MMI units 215 with the exception that it has been modified to allow it to communicate with the simulation unit's 305 communication application 340.
- the MMI 355 will typically have a graphical display and appropriate input/output device (such as, for example, a mouse), a keyboard, and a graphical user interface.
- a graphical display and appropriate input/output device (such as, for example, a mouse), a keyboard, and a graphical user interface.
- Any of the foregoing variations may be implemented by programming a suitable general-purpose computer that has the requisite network connections.
- the programming may be accomplished through the use of a program storage device readable by the computer and encoding a program of instructions executable by the computer for performing the operations described above.
- the program storage device may take the form of, e.g. , one or more floppy disks; CD ROMs or other optical disks; magnetic tapes; read-only memory chips (ROM); and other forms of the kind well-known in the art or subsequently developed.
- instructions may be "object code,” i.e. , in binary form that is executable more-or- less directly by the computer; in "source code” that requires compilation or interpretation before execution; or in some intermediate form such as partially compiled code.
- object code i.e. , in binary form that is executable more-or- less directly by the computer
- source code that requires compilation or interpretation before execution
- intermediate form such as partially compiled code.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002256507A CA2256507A1 (en) | 1996-05-28 | 1997-05-02 | Real-time process control simulation method and apparatus |
AU28254/97A AU2825497A (en) | 1996-05-28 | 1997-05-02 | Real-time process control simulation method and apparatus |
DE19781804A DE19781804B4 (en) | 1996-05-28 | 1997-05-02 | Device for simulating a real-time process control |
GB9825598A GB2328523B (en) | 1996-05-28 | 1997-05-02 | Real-time process control simulation method and apparatus |
DE19781804T DE19781804T1 (en) | 1996-05-28 | 1997-05-02 | Method and device for simulating real-time process control |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/654,355 | 1996-05-28 | ||
US08/654,355 US5752008A (en) | 1996-05-28 | 1996-05-28 | Real-time process control simulation method and apparatus |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1997045778A1 true WO1997045778A1 (en) | 1997-12-04 |
Family
ID=24624529
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1997/007461 WO1997045778A1 (en) | 1996-05-28 | 1997-05-02 | Real-time process control simulation method and apparatus |
Country Status (8)
Country | Link |
---|---|
US (1) | US5752008A (en) |
AU (1) | AU2825497A (en) |
CA (1) | CA2256507A1 (en) |
DE (2) | DE19781804B4 (en) |
GB (1) | GB2328523B (en) |
MY (1) | MY119998A (en) |
TW (1) | TW494356B (en) |
WO (1) | WO1997045778A1 (en) |
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Also Published As
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DE19781804B4 (en) | 2008-09-25 |
GB2328523B (en) | 2000-02-02 |
DE19781804T1 (en) | 1999-05-12 |
GB9825598D0 (en) | 1999-01-13 |
TW494356B (en) | 2002-07-11 |
MY119998A (en) | 2005-08-30 |
GB2328523A (en) | 1999-02-24 |
CA2256507A1 (en) | 1997-12-04 |
US5752008A (en) | 1998-05-12 |
AU2825497A (en) | 1998-01-05 |
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