System and method for monitoring changes in process dynamic behavior by mapping parameters to a lower dimensional space

Patent metadata

Field	Value
Publication number	US-10976718-B2
Application number	US-201916294812-A
Country	US
Kind code	B2
Filing date	Mar 6, 2019
Priority date	Mar 6, 2019
Publication date	Apr 13, 2021
Grant date	Apr 13, 2021

Abstract

A method includes acquiring process data collected in an industrial process control and automation system. The method also includes reducing a dimension space of the process data by combining two or more parameters of the process data or examining a frequency response of the process data. The method further includes determining a change in a process based on a change in the process data in the reduced dimension space. The method also includes outputting a result based on the determined change in the process.

First claim

What is claimed is:

1. A method for monitoring changes in process dynamic behavior in an industrial process using a device including a processing device, a memory and a communication unit, the method comprising:
acquiring, by the processing device, process data collected and stored in the memory of the device and from one or more controllers through a plurality of sensors or actuator associated with an industrial process control and automation system;
reducing, by the processing device, a dimension space of the process data by combining two or more parameters of the process data or examining a frequency response of the process data, the dimension space of the process data is reduced by combining a time constant parameter and a time delay parameter into a response time parameter, wherein the response time parameter is the sum of the time constant parameter and the time delay parameter;
determining, by the processing device, a change in a process based on a change in the process data in the reduced dimension space;
outputting, by the communication unit of the device, a result based on the determined change in the process; and
adjusting the industrial process control and automation system using the result to re-tune or calibrate a component of the industrial process control and automation system.

2. The method of claim 1 , wherein the dimension space of the process data is reduced by reducing a higher order model to a response time parameter.

3. The method of claim 1 , wherein the dimension space of the process data is reduced to a gain and a phase shift of the process data at a cut-off frequency.

4. The method of claim 1 , wherein the process data is acquired from one or more controllers in the industrial process control and automation system.

5. The method of claim 1 , wherein the change in the process is determined by inputting the process data in the reduced dimension space into an algorithm and receiving an output of the algorithm indicating that the process data has exceeded a predetermined threshold.

6. The method of claim 1 , wherein the result that is output comprises an alarm or warning to a user, the alarm or warning indicating to the user to re-tune or calibrate a component of the industrial process control and automation system.

7. The method of claim 1 , wherein the result that is output comprises a signal or instruction transmitted to a component of the industrial process control and automation system, wherein the signal or instruction is configured to automatically change a setting of the component.

8. The method of claim 1 , wherein the method is performed by a cloud-based computing device.

9. An apparatus for monitoring changes in the dynamic behavior of an industrial process comprising:
at least one processing device, a memory and a communication unit configured to:
acquire process data collected and stored in the memory of the apparatus and from one or more controllers through a plurality of sensors or actuator associated with an industrial process control and automation system;
reduce a dimension space of the process data by combining two or more parameters of the process data or examining a frequency response of the process data, the dimension space of the process data is reduced by combining a time constant parameter and a time delay parameter into a response time parameter, wherein the response time parameter is the sum of the time constant parameter and the time delay parameter;
determine a change in a process based on a change in the process data in the reduced dimension space;
output, by the communication unit, a result based on the determined change in the process; and
adjust the industrial process control and automation system using the result to re-tune or calibrate a component of the industrial process and automation system.

10. The apparatus of claim 9 , wherein to reduce the dimension space of the process data, the at least one processing device is configured to reduce a higher order model to a response time parameter.

11. The apparatus of claim 9 , wherein to reduce the dimension space of the process data, the at least one processing device is configured to reduce the dimension space to a gain and a phase shift of the process data at a cut-off frequency.

12. The apparatus of claim 9 , wherein the at least one processing device is configured to acquire the process data from one or more controllers in the industrial process control and automation system.

13. The apparatus of claim 9 , wherein to determine the change in the process, the at least one processing device is configured to input the process data in the reduced dimension space into an algorithm and receive an output of the algorithm indicating that the process data has exceeded a predetermined threshold.

14. The apparatus of claim 9 , wherein to output the result, the at least one processing device is configured to output an alarm or warning to a user, the alarm or warning indicating to the user to re-tune or calibrate a component of the industrial process control and automation system.

15. The apparatus of claim 9 , wherein to output the result, the at least one processing device is configured to transmit a signal or instruction to a component of the industrial process control and automation system, wherein the signal or instruction is configured to automatically change a setting of the component.

16. The apparatus of claim 9 , wherein the apparatus is comprised in a cloud-based computing device.

17. A non-transitory computer readable medium containing instructions that when executed cause at least one processing device to monitor changes in process dynamic behavior of an industrial process using a device, the device further including a memory and a communication unit:
acquire process data collected and stored in the memory of the device and from one or more controllers through a plurality of sensors or actuator associated with an industrial process control and automation system;
reduce a dimension space of the process data by combining two or more parameters of the process data or examining a frequency response of the process data, the dimension space of the process data is reduced by combining a time constant parameter and a time delay parameter into a response time parameter, wherein the response time parameter is the sum of the time constant parameter and the time delay parameter;
determine a change in a process based on a change in the process data in the reduced dimension space;
output, by the communication unit, a result based on the determined change in the process; and
adjust the industrial process control and automation system using the result to retune or calibrate a component of the industrial process and automation system.

Assignees

• Honeywell Ltd

Inventors

• Forbes Michael
• Backstrom Johan
• Stewart Gregory E

Classifications

• G05B23/0221

  Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods · CPC title

• G05B23/0232 Primary

  based on qualitative trend analysis, e.g. system evolution · CPC title

• G05B2219/33051

  BBC behavior based control, stand alone module, cognitive, independent agent · CPC title

• G05B19/406 Primary

  characterised by monitoring or safety (G05B19/19 takes precedence) · CPC title