GB2283116A - Data verification in a process control system - Google Patents
Data verification in a process control system Download PDFInfo
- Publication number
- GB2283116A GB2283116A GB9321859A GB9321859A GB2283116A GB 2283116 A GB2283116 A GB 2283116A GB 9321859 A GB9321859 A GB 9321859A GB 9321859 A GB9321859 A GB 9321859A GB 2283116 A GB2283116 A GB 2283116A
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- GB
- United Kingdom
- Prior art keywords
- data
- relational
- record
- item
- verifier
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000004886 process control Methods 0.000 title claims abstract description 15
- 238000013524 data verification Methods 0.000 title claims description 12
- 238000000034 method Methods 0.000 claims abstract description 30
- 230000008569 process Effects 0.000 claims abstract description 30
- 238000012795 verification Methods 0.000 claims description 11
- 238000012790 confirmation Methods 0.000 claims description 9
- 238000012544 monitoring process Methods 0.000 claims description 6
- 238000001514 detection method Methods 0.000 claims description 4
- 230000003993 interaction Effects 0.000 claims description 3
- 230000003213 activating effect Effects 0.000 claims description 2
- 230000001172 regenerating effect Effects 0.000 claims description 2
- 241000237519 Bivalvia Species 0.000 claims 1
- 235000020639 clam Nutrition 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000003860 storage Methods 0.000 description 5
- 238000012824 chemical production Methods 0.000 description 2
- 230000008901 benefit Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011112 process operation Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F11/00—Error detection; Error correction; Monitoring
- G06F11/07—Responding to the occurrence of a fault, e.g. fault tolerance
- G06F11/0703—Error or fault processing not based on redundancy, i.e. by taking additional measures to deal with the error or fault not making use of redundancy in operation, in hardware, or in data representation
- G06F11/0751—Error or fault detection not based on redundancy
- G06F11/0763—Error or fault detection not based on redundancy by bit configuration check, e.g. of formats or tags
-
- 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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
-
- 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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
-
- 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
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31483—Verify monitored data if valid or not by comparing with reference value
-
- 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
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31484—Operator confirms data if verified data is correct, otherwise amends data
-
- 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
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31485—Verify and update all related data in relational database
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Landscapes
- Engineering & Computer Science (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Automation & Control Theory (AREA)
- Testing And Monitoring For Control Systems (AREA)
- Control By Computers (AREA)
Abstract
A process controller (1) includes an input interface (2) for reception of data. The interface (2) may be a serial port for receiving signals from sensors such as temperature sensors. Alternatively, it may simply be a keypad. A data monitor (4), a data verifier (5) and a relational record update circuit (7) ensure that all data whether relational or independent is automatically verified in an efficient manner to prevent writing of incorrect data to records (11) and (12). These records form the basis for the generation of output signals which may be time driven to initiate events for process control. Verifier 5 compares non-relational input data in buffer (9) against reference values from a file (6), and also checks at (10) whether complete sets of data have been entered. <IMAGE>
Description
"Data Verification in a Process Control System"
The invention relates to process control systems.
The function of a process control system is to capture data and to output instructions or command signals which directly or indirectly control the carrying out of various process operations. In a manufacturing plant production line, a process controller outputs instructions for the automatic and semi-automatic production of products such as automobiles. In the office environment, a computerised process control system generates screen, printer and sound outputs which may indicate that work is to be carried out by certain deadline dates, and also generates the documents which are used in the process.
Irrespective of the nature of the process being controlled, it is absolutely essential that the process controller operates using correct data. One incorrect item of data may lead in a "chain reaction" to several incorrect items of data and to erroneous control signals being outputted. This can have disastrous consequences for the particular process. For example, in the office environment an incorrect deadline date for the compliance with formalities involved in the incorporation of a company can lead to major problems. In the chemical production field, an incorrect control signal relating to temperature could lead to a whole batch of a particular compound being wasted.
United States Patent Specification No. US 4,499,584 (U.S.A.) describes an apparatus for injecting spurious signals for incoming data at a recorder. The apparatus includes sensors and associated data channels. Data inputted on a data channel and not appearing on the blind channel enters the recorder without interruption. This prior art illustrates the fact that quite an amount of work has been carried out in the manner in which data signals are handled and transmitted in an improved manner.
However, if the data is incorrect to begin with no amount of spurious signal elimination will solve this problem.
The simplest example is where an operator inputs wrong data into a data record of the process controller.
Another example is where a wrong sensor is connected up to an input port of the controller in a chemical production plant.
British patent specification No. GB-B-2, 194, 655 discloses a system for capture of data in the form of analogue inputs. Several microprocessor units carry out operations on the received data. In many situations, it is not practical to operate in this manner as only one processor unit may be available because of the nature of the process control.
The invention is erected towards providing a data verification process carried out by a process controller to overcome these problems.
According to the invention, there is provided a data verification process comprising the steps of:
the input controller writing data received at an
input interface to a primary buffer memory circuit
and setting a flag in the memory circuit to an
invalid status for each data item received;
a data monitor reading each inputted data item to
detect if it is relational or non-relational;
for each non-relational item a data verifier
comparing it with a set of reference values stored in a reference file, changing the status flag to valid if verified and outputting an error message if invalid; for each relational data item, the data verifier verifying the item and activating a relational record update circuit which in turn updates a related parameter value which is common to a plurality of records; and the data verifier writing all of the data items for which the status flag is valid to a seccndary buffer memory circuit; the data monitor detecting if all of a set of data has been received and if so, directing display of an operator prompt for inputting of a data confirmation signal, if a positive confirmation signal is received, the data verifier automatically transmitting the data from the secondary buffer to a data record, if a negative confirmation signal is received, the data verifier re-setting the status flag of the data item to be amended, and carrying out the verification operations on the amended data item inputted and subsequently writing the data items to the data record after all flags are set to valid status; the data monitor monitoring all amendment instructions inputted for detection of such an instruction for a relational data item,
on detection of such an instruction, the
relational record update circuit re-setting the
value of the linked parameter value and upon
completion of data verification operations of the
data verifier automatically retrieving all related
or linked data items, and regenerating the
parameter value; and
an output device driver generating process control
commands using data retrieved from the data record
and the relational record.
In one embodiment, the data record and the relational record are automatically written to a particular partitioned section of a fixed disk associated with the inputted data, the section being determined by the data monitor.
Preferably the-reference values reference values are in the range of 1 to 3 bytes in size for fast verification and user interaction.
In another embodiment, the data monitor transmits instructions to a distributed processor for local data monitoring and verification.
In a still further embodiment, the process comprises the further steps of the output device driver repeatedly monitoring a real time clock and being activated when preset times associated with data records are reached, the device driver when activated retrieving the data record associated with the time event and retrieving relational parameters associated with it; and generating output process control signals according to the event.
The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawing, which is a diagram showing the manner in which the process of the invention is carried out.
Referring to the drawing, there is illustrated a process controller and a data verification process carried out by it. The process controller may be for the control of a manufacturing process, or for the control of work carried out in an office in which the "end" product may be a process control instruction paper record.
As shown in the drawing, there is a process controller 1 which includes an input interface 2. Depending on the circumstances, this can be an input port for a microcomputer for connection to sensors, or in addition or alternatively it may be a keyboard or keypad. The input interface 2 is connected to an input controller 3. The process controller 1 also includes a data monitor circuit 4, and a data verifier 5 which is connected to a storage device storing a reference data file 6. There is a relational record update circuit 7 which is connected to a storage device storing a relational reference file 8.
The input interface 2 is connected to a primary buffer memory circuit 9, which is in turn connected to a secondary buffer memory circuit 10. The output of the buffer circuit 10 is connected to memory circuits for a data record 11 and for a relational-record 12. These are in turn connected to a fixed disk storage device 13 which is partitioned into eleven sections a, b, ...... 1. The process controller 1 also includes an output device drivers 14 connected to a real time clock 15 and also connected for retrieval of data from the storage device 13. The drivers 14 drive output devices 16. In the example described below, the output device drivers includes screen and printer controllers and the output devices 16 are video screens and printers. However, the output devices may be any particular process control output devices such as a robotic item of equipment on a production line.
The data verification process involves initially receiving data at the input interface 2 in response to prompts displayed at a video screen. However, a simple LCD display could be used instead. An important aspect of the data inputting process is that pre-defined reference values for data to be inputted are also displayed together with the prompts. In this embodiment the reference values are -only 2 bytes long so that the display device is not cluttered and so that the operator may easily remember them. This also allows use of a small LCD where the controller is relatively small. Another advantage is that the verification operations may be carried out relatively quickly by the processors. The input controller 3 automatically writes the data to the primary buffer 9 and at the same time it sets a flag in the primary buffer 9 associated with each item of data to indicate verification status. The flag is initially set to an "invalid" status.
Subsequently, the data monitor 4 is activated and this reads each inputted data item to detect if it is relational or non-relational. The data monitor may be implemented by a set of instructions transmitted from a master controller to a slave controller which includes the input interface 2 for reception of the data. This allows distributed data verification in a complex process controller. The step above of the input controller directing display of data inputting fields applies only if the input interface is a keyboard. Where data is received via a link such as an RS232 link directly into a port of the process controller, of course no such displays are involved. However, the inputted data must be configured according to the set of pre-defined reference values.
For each non-relational data item detected by the monitor 4, the data verifier 5 compares the data item with a set of reference values stored in the reference data file 6.
This is a very simple set of operations which may be carried out in a relatively small number of processor cycles, as they involve direct comparisons between each data item in the primary buffer 9 with the reference values in the file 6. For each data item which complies with the reference values the status flag is set to "valid" status and the item is written to the secondary buffer memory circuit 10. If invalid, a signal is transmitted to an output device such as a file for later printing to indicate to an operator, or immediately to an output screen for a data processing system.
or each relational data item, the data verifier 5 verifies the item in the same way, but in addition it activates the relational record update circuit 7 which accesses the relational record 12 and updates a related data item. For example, where the inputted data relates to temperature at various parts of a liquid chemical bulk tank, the related data item in the record 12 may be the average temperature, which of course depends on the output from a number of different temperature sensors. Again, once verified and processed by the update circuit 7 each relational data item is written to the secondary buffer 10.
The data monitor 4 then reads the data in the secondary buffer 10 to determine if all of a set of data has been received. For example, there may be a required set of output signals from a particular sensor, or indeed a set of data being inputted on a keyboard for a particular display panel. If all of a set of data has been detected by the monitor 4, it directs display of an operator prompt for inputting of a data confirmation signal. This operator interaction step has been found to be particularly important in ensuring that data which has been inputted from whatever source is correct. If a positive confirmation signal is inputted, the verifier 5 automatically transmits the data from the secondary buffer 10 to the data record 11. However, if a negative confirmation signal is inputted, the data verifier re-sets the status flag of the dr.ta item to be amended, and carries out the verification operations on the amended data item and subsequently writes the data item to the data-record after all the flags have been set to the valid status. It has been found that by re-setting the status flag stored in the primary buffer 9, links are established for operation by the verifier 5 in ensuring that all data has been verified in the correct manner. The set of status flags in the primary buffer 9 effectively track each data item to ensure that complete verification is carried out before writing to the data record 11.
On an on-going basis, the data monitor 4 monitors all amendments instructions which are received such as update signals from a sensor or keyed manual over-ride instructions for amendment of data items. When this happens, the data verifier operates as described above for verification. Where the data is relational, operation of the update circuit 7 is extremely important in these circumstances and the update circuit 7 re-sets the value of the linked parameter value in the related record 12.
Upon completion of a data verification operation of the verifier 5, the circuit 7 automatically retrieves all related or linked data items and re-generates the parameter value in the relational record 12.
Operation of the output device drivers 14 is dependent entirely on the data which is in the records 11 and 12.
The drivers 14 repeatedly poll a real-time clock 15 and become re-activated when pre-set times associated with data records are reached. The drivers 14 have pre-set events which are initiated according to real time and according to particular data records 11 and 12. These are of course retrieved from the storage device 13 after writing of the records 11 and 12 to the device 13. An important aspect of the invention is the manner in which output signals may be transmitted by the drivers 14 which incorporate both the data which has been inputted and the related data so that various different events may be linked for integrated process control.
It will be appreciated that the invention provides for the correct operation of a process controller by ensuring verification of data being received in an extremely simple and efficient manner.
The invention is not limited to the embodiments hereinbefore described, but may be varied in construction and detail.
Claims (6)
1. A data verification process carried out by a
process control system, the process comprising the
steps of:
the input controller writing data received at an
input interface to a primary buffer memory circuit
and setting a flag in the memory circuit to an
invalid status for each data item received;
a data monitor reading ecch inputted data item to
detect if it is relational or non-relational;
for each non-relational item a data verifier
comparing it with a set of reference values stored
in a reference file, changing the status flag to
valid if verified and outputting an error message
if invalid;
for eacn relational data item, the data verifier
verifying the item and activating a relational
record update circuit which in turn updates a
related parameter value which is common to a
plurality of records; and
the data verifier writing all of the data items
for which the status flag is valid to a secondary
buffer memory circuit;
the data monitor detecting if all of a set of data
has been received and if so, directing display of
an operator prompt for inputting of a data
confirmation signal,
if a positive confirmation signal is received, the
data verifier automatically transmitting the data
from the secondary buffer to a data record,
if a negative confirmation signal is received, the
data verifier re-setting the status flag of the
data item to be amended, and carrying out the
verification operations on the amended data item
inputted and subsequently writing the data items
to the data record after all flags are set to
valid status;
the data monitor monitoring all amendment
instructions inputted for detection of such an
instruction for a relational data item,
on detection of such an instruction, the
relational record update circuit re-setting the
value of the linked parameter value and upon
completion of data verification operations of the
data verifier automatically retrieving all related
or linked data items, and regenerating the
parameter value; and
an output device driver generating process control
commands using data retrieved from the data record
and the relational record.
2. A process as claimed in Claim 1, wherein the data
record and the relational record are automatically
written to a particular partitioned section of a
fixed disk associated with the inputted data, the
section being determined by the data monitor.
3. A process as claimed in Claims 1 or 2 wherein the
reference values are in the range of 1 to 3 bytes
in size for fast verification and user
interaction.
4. A process as claimed in any of Clams 1 to 3
wherein the data monitor transmits instructions to
a distributed processor for local data monitoring
and verification.
5. A process as claimed in any preceding claim
comprising the further steps of
the output device driver repeatedly monitoring a real time clock and being
activated when pre-set times associated with
data records are reached,
the device driver when activated retrieving
the data record associated with the time
event and retrieving relational parameters
associated with it; and
generating output process control signals
according to the event.
6. A process substantially as hereinbefore described
with reference to and as illustrated in the
accompanying drawing.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9321859A GB2283116A (en) | 1993-10-22 | 1993-10-22 | Data verification in a process control system |
| BE9301210A BE1005870A6 (en) | 1993-10-22 | 1993-11-04 | VERIFICATION OF DATA IN A PROCESS CONTROL SYSTEM. |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9321859A GB2283116A (en) | 1993-10-22 | 1993-10-22 | Data verification in a process control system |
| BE9301210A BE1005870A6 (en) | 1993-10-22 | 1993-11-04 | VERIFICATION OF DATA IN A PROCESS CONTROL SYSTEM. |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9321859D0 GB9321859D0 (en) | 1993-12-15 |
| GB2283116A true GB2283116A (en) | 1995-04-26 |
Family
ID=25662806
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9321859A Withdrawn GB2283116A (en) | 1993-10-22 | 1993-10-22 | Data verification in a process control system |
Country Status (2)
| Country | Link |
|---|---|
| BE (1) | BE1005870A6 (en) |
| GB (1) | GB2283116A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1420311A1 (en) * | 2002-11-12 | 2004-05-19 | Infineon Technologies AG | Method and apparatus for computer-based monitoring of process parameters in a production process |
| EP1662346A2 (en) * | 2004-11-26 | 2006-05-31 | Endress + Hauser Wetzer GmbH + Co. KG | Method for secure parametrisation of a field device in automation technology |
| EP2341406A1 (en) * | 2009-12-23 | 2011-07-06 | Siemens Milltronics Process Instruments Inc. | Method for safely parameterizing an electrical device |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2260627A (en) * | 1991-10-31 | 1993-04-21 | Pettit | Data integrity in a project control apparatus |
| GB2262639A (en) * | 1991-11-19 | 1993-06-23 | Norton Holdings Limited | Improving data integrity for document generation |
-
1993
- 1993-10-22 GB GB9321859A patent/GB2283116A/en not_active Withdrawn
- 1993-11-04 BE BE9301210A patent/BE1005870A6/en not_active IP Right Cessation
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2260627A (en) * | 1991-10-31 | 1993-04-21 | Pettit | Data integrity in a project control apparatus |
| GB2262639A (en) * | 1991-11-19 | 1993-06-23 | Norton Holdings Limited | Improving data integrity for document generation |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1420311A1 (en) * | 2002-11-12 | 2004-05-19 | Infineon Technologies AG | Method and apparatus for computer-based monitoring of process parameters in a production process |
| US7027943B2 (en) | 2002-11-12 | 2006-04-11 | Infineon Technologies Ag | Method, device, computer-readable storage medium and computer program element for the computer-aided monitoring of a process parameter of a manufacturing process of a physical object |
| EP1662346A2 (en) * | 2004-11-26 | 2006-05-31 | Endress + Hauser Wetzer GmbH + Co. KG | Method for secure parametrisation of a field device in automation technology |
| EP1662346A3 (en) * | 2004-11-26 | 2010-04-28 | Endress + Hauser Wetzer GmbH + Co. KG | Method for secure parametrisation of a field device in automation technology |
| EP2341406A1 (en) * | 2009-12-23 | 2011-07-06 | Siemens Milltronics Process Instruments Inc. | Method for safely parameterizing an electrical device |
| US8634938B2 (en) | 2009-12-23 | 2014-01-21 | Siemens Aktiengesellschaft | Method for safely parameterizing an electrical device |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9321859D0 (en) | 1993-12-15 |
| BE1005870A6 (en) | 1994-02-22 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |