Systems and methods for controlling asset operation using stream-based processing in multi-node networks

Patent metadata

Field	Value
Publication number	US-11048238-B2
Application number	US-201916252849-A
Country	US
Kind code	B2
Filing date	Jan 21, 2019
Priority date	Nov 13, 2018
Publication date	Jun 29, 2021
Grant date	Jun 29, 2021

Abstract

A system includes a first asset disposed in an industrial environment configured to perform one or more operations, a second asset disposed in the industrial environment, and a server device communicatively coupled to the first asset and the second asset. The server device is configured to receive a first set of stream-based data from the first asset, receive a second set of stream-based data from the second asset, wherein the first set of stream-based data and the second set of stream-based data are received in real time or near real time, determine whether the one or more operations are within a threshold based on a comparison of the first set of stream-based data with respect to the second set of stream-based data, and send a command to the first asset or the second asset in response to the one or more operations being outside the threshold.

First claim

The invention claimed is:

1. A system, comprising:
a first asset disposed in an industrial environment configured to perform one or more operations;
a second asset disposed in the industrial environment; and
a server device communicatively coupled to the first asset and the second asset, wherein the server device is configured to:
receive a first set of stream-based data from the first asset;
receive a second set of stream-based data from the second asset, wherein the first set of stream-based data and the second set of stream-based data are received in real time or near real time;
determine whether the one or more operations are within a threshold based on a comparison of the first set of stream-based data with respect to the second set of stream-based data;
send a command to the first asset or the second asset in response to the one or more operations being outside the threshold;
determine whether a first value for a first data field of the first set of stream-based data remains unchanged while a second value for a second data field of the second set of stream-based data changes for greater than a threshold period of time; and
send a notification to a computing device indicative of the first value not changing with respect to the second value.

2. The system of claim 1 , wherein the first asset and the second asset are configured to assist extracting hydrocarbons from a reservoir.

3. The system of claim 2 , wherein the first asset is downstream from the second asset.

4. The system of claim 1 , wherein the server device is configured to:
identify a first portion of the first set of stream-based data having a first type of data;
identify a second portion of the second set of stream-based data having the first type of data; and
determine whether the one or more operations are within the threshold based on the comparison, wherein the comparison is based on the first portion of the first set of stream-based data with respect to the second portion of the second set of stream-based data.

5. The system of claim 4 , wherein the server device is configured to determine the first type of data based on metadata of the first portion and the second portion.

6. The system of claim 4 , wherein the server device is configured to: identify an analysis engine configured to analyze data of the first data type; and send the first portion and the second portion to the analysis engine.

7. The system of claim 6 , wherein the analysis engine is configured to:
compare the first portion to the second portion to determine whether the one or more operations are within the threshold; and
generate the command in response to the one or more operations being outside the threshold.

8. The system of claim 1 , wherein the command is configured to adjust a first set of properties of the first asset, a second set of properties of the second asset, or both to cause the one or more operations to be within the threshold.

9. The system of claim 1 , wherein the threshold is associated with an output of an industrial system in the industrial environment.

10. The system of claim 9 , wherein the industrial system comprises a hydrocarbon extraction system, a mining system, or a food processing system.

11. The system of claim 1 , wherein the server device is configured to:
identify a condition associated with the one or more operations being outside the threshold based on the first set of stream-based data and the second set of stream-based data;
store relationship data between the condition, the first set of stream-based data, and the second set of stream-based data in a database;
train a machine learning model associated with the one or more operations based on the relationship data; and
monitor a third set of stream-based data from the first asset and a fourth set of stream-based data for the condition based on the machine learning model.

12. A system, comprising:
a first asset disposed in an industrial environment configured to perform one or more operations;
a second asset disposed in the industrial environment; and
a server device communicatively coupled to the first asset and the second asset, wherein the server device is configured to:
receive a first set of stream-based data from the first asset;
receive a second set of stream-based data from the second asset, wherein the first set of stream-based data and the second set of stream-based data are received in real time or near real time;
determine whether the one or more operations are within a threshold based on a comparison of the first set of stream-based data with respect to the second set of stream-based data;
identify a condition associated with the one or more operations being outside the threshold based on the first set of stream-based data and the second set of stream-based data;
determine a remedial action in response to the one or more operations being outside the threshold;
request approval to take the remedial action;
send a command to the first asset or the second asset to take the remedial action in response to receiving approval to take the remedial action
store relationship data between the condition, the first set of stream-based data, and the second set of stream-based data in a database;
train a machine learning model associated with the one or more operations based on the relationship data; and
monitor a third set of stream-based data from the first asset and a fourth set of stream-based data for the condition based on the machine learning model.

13. The system of claim 12 , wherein the server device is configured to:
determine whether a first value for a first data field of the first set of stream-based data remains unchanged while a second value for a second data field of the second set of stream-based data changes for greater than a threshold period of time; and
send a notification to a computing device indicative of the first value not changing with respect to the second value.

14. The system of claim 12 , wherein the server device is configured to:
identify a first portion of the first set of stream-based data having a first type of data;
identify a second portion of the second set of stream-based data having the first type of data; and
determine whether the one or more operations are within the threshold based on the comparison, wherein the comparison is based on the first portion of the first set of stream-based data with respect to the second portion of the second set of stream-based data.

15. The system of claim 14 , wherein the server device is configured to:
identify an analysis engine configured to analyze data of the first data type; and send the first portion and the second portion to the analysis engine.

16. A method, comprising:
receiving a first set of stream-based data from a first asset, wherein the first asset is disposed in an industrial environment and configured to perform one or more operations;
identifying a first portion of the first set of stream-based data having a first type of data;
storing the first set of stream-based data in a memory;
receiving a second set of stream-based data from a second asset disposed in the industrial environment, wherein the first set of stream-based data and the second set of stream-based data are received in real time or near real time;
identifying a second portion of the second set of stream-based data having the first type of data;
storing the second set of stream-based data in the memory;
determining, via a processor, whether the one or more operations are within a threshold based on a comparison of the first set of stream-based data with r

Assignees

• Rockwell Automation Tech Inc

Inventors

• Gray Edward A
• Weatherhead Norman A
• Mashetty Srikanth G

Classifications

• G05B19/41835 Primary

  characterised by program execution · CPC title

• G05B19/4148

  characterised by using several processors for different functions, distributed (real-time) systems (G05B19/4141 takes precedence) · CPC title

• G05B2219/31449

  Monitor workflow, to optimize business, industrial processes · CPC title

• G05B2219/33338

  DNC distributed, decentralised nc, concurrent, multiprocessing · CPC title

• Y02P90/02

  Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] · CPC title