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

Patent metadata

Field	Value
Publication number	US-11656607-B2
Application number	US-202117332170-A
Country	US
Kind code	B2
Filing date	May 27, 2021
Priority date	Nov 13, 2018
Publication date	May 23, 2023
Grant date	May 23, 2023

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 server device communicatively coupled to a first asset and a second asset, wherein the first and second assets each perform one or more steps of an industrial process, wherein the server device is configured to perform operations comprising:
receiving a first set of stream-based data from the first asset;
receiving 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;
identifying a condition of the second asset based on a comparison of the first set of stream-based data to the second set of stream-based data;
identifying a remedial action to address the condition of the second asset based on the first set of stream-based data, the second set of stream-based data, the comparison of the first set of stream-based data to the second set of stream-based data, the condition, or a combination thereof, wherein the remedial action comprises adjusting one or more operational parameters of the second asset to cause one or more operations of the second asset to be within one or more expected ranges of values for the second set of stream-based data;
generating a command to implement the remedial action; and
transmitting the command to the second asset.

2. The system of claim 1 , wherein the server device is configured to perform the operations comprising identifying the condition by:
determining a degree of truth value for each of a plurality of possible conditions associated with the second asset; and
determining that a first degree of truth value for one or the plurality of possible conditions exceeds a threshold degree of truth value.

3. The system of claim 2 , wherein the respective degree of truth value for each of the plurality of possible conditions is determined via one or more truth tables based on the first set of stream-based data, the second set of stream-based data, the comparison of the first set of stream-based data to the second set of stream-based data, or a combination thereof.

4. The system of claim 2 , wherein the server device is configured to perform the operations comprising:
determining that the first set of stream-based data and the second set of stream-based data are of a common data type;
identifying drift in the second set of stream-based data based on the comparison of the first set of stream-based data to the second set of stream-based data; and
adjusting the threshold degree of truth value based on the drift in the second set of stream-based data.

5. The system of claim 4 , wherein the server device is configured to perform the operations comprising determining that the first set of stream-based data and the second set of stream-based data are of the common data type by referencing metadata for the first set of stream-based data and the second set of stream-based data.

6. The system of claim 1 , wherein the server device is configured to perform the operations comprising identifying the condition of the second asset by performing one or more fuzzy logic calculations on the first set of stream-based data, the second set of stream-based data, the comparison of the first set of stream-based data to the second set of stream-based data, or a combination thereof.

7. The system of claim 1 , wherein the server device is configured to perform the operations comprising identifying the remedial action to address the condition of the second asset by referencing a decision table based on the first set of stream-based data, the second set of stream-based data, the comparison of the first set of stream-based data to the second set of stream-based data, the condition, or a combination thereof.

8. The system of claim 1 , wherein identifying the remedial action to address the condition of the second asset comprises referencing historical data in which the condition occurred.

9. The system of claim 1 , wherein the server device is configured to perform the operations comprising identifying the condition by:
generating a model for the second asset based on the first set of stream-based data;
generating, via the model, the one or more expected ranges of values for the second set of stream-based data;
comparing the second set of stream-based data to the one or more expected ranges of values for the second set of stream-based data;
determining that the second set of stream-based data includes one or more data points that are outside of the one or more expected ranges of values for the second set of stream-based data; and
identifying the condition of the second asset based on the one or more data points of the second set of stream-based data being outside of the one or more expected ranges of values for the second set of stream-based data.

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

11. The system of claim 1 , wherein the first asset is downstream from the second asset.

12. The system of claim 1 , wherein the server device is configured to perform the operations comprising:
storing, in a database, relationship data identifying a relationship between the condition and the second set of stream-based data;
training a machine learning model based on the relationship data; and
receiving a third set of stream-based data; and
identifying, via the machine learning model, the condition based on the third set of stream-based data.

13. A method, comprising:
receiving, via a processor, a first set of stream-based data from a first asset disposed in an industrial environment;
receiving, via the processor, 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;
determining, via the processor, a respective degree of truth value for each of a plurality of possible conditions for the second asset based on a comparison of the first set of stream-based data to the second set of stream-based data; and
determining, via the processor, that the respective degree of truth value for a condition of the plurality of possible conditions for the second asset exceeds a threshold degree of truth value;
identifying, via the processor, a remedial action to address the condition of the second asset based on the first set of stream-based data, the second set of stream-based data, the comparison of the first set of stream-based data to the second set of stream-based data, the condition, or a combination thereof, wherein the remedial action comprises adjusting one or more operational parameters of the second asset to cause one or more operations of the second asset to be within one or more expected ranges of values for the second set of stream-based data;
generating, via the processor, a command to implement the remedial action; and
transmitting, via the processor, the command to the second asset.

14. The method of claim 13 , comprising:
determining that the first set of stream-based data and the second set of stream-based data are of a common data type by referencing metadata for the first set of stream-based data and the second set of stream-based data;
identifying drift in the second set of stream-based data based on the comparison of the first set of stream-based data to the second set of stream-based data; and
adjusting the threshold degree of truth value based on the drift in the second set of stream-based data.

15. The method of claim 13 , comprising:
storing, in a database,

Assignees

• Rockwell Automation Tech Inc

Inventors

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

Classifications

• G05B2219/31449

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

• G05B19/41835 Primary

  characterised by program execution · CPC title

• Y02P90/02

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

• G05B19/4148

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

• G05B2219/33338

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