Abstract: There is described a method for operating a process plant, in which a number of alarm notifications for indicating non-compliant operating events of the process plant are generated at process level. Alarm notifications which can be generated during the operation of the process plant are defined. At least a number of the generatable alarm notifications are assigned, in each case at least a first value or a second value as a dependency value. A current process state of the process plant is determined and depending on the determined process state, those alarm notifications to which the first value was assigned as a dependency value are not indicated.

Abstract: A warning system for use with a climbing wall and an automatic belay apparatus for belaying a climber, the warning system providing a warning that a climber is not protected by the auto-belay apparatus. The warning system includes a sensor positioned to sense that a lower end of the climbing rope is secured to the climbing wall and the climber is not attached to the auto-belay system which indicates a dangerous situation, and a height sensor for sensing when the climber has reached a selected height on the climbing wall. A processor receives signals from the sensors and compares the signals to determine if the climber has reached the selected height with the lower end of the climbing wall still secured to the wall, and if so, then actuates a warning alarm.

Abstract: A simulation system attaches to a configuration database for one or more fully configured nodes of a process control system and copies the modules within those nodes into one or more simulation computers as simulation modules. The simulation system includes an algorithm that automatically creates a reference parameter module for each of the copied nodes that stores a reference parameter for each of the inputs, outputs or other references to signals external to the nodes. In the case of the Fieldbus function blocks, the simulation system automatically creates a function block within the simulation workstation in the protocol of the controller node which mimics the operation of the Fieldbus function block, and then creates the simulation system having those mimicked Fieldbus function blocks operating as if they had originally been configured to be in the controller being simulated, instead of within a field device external to the controller.

Abstract: The present invention relates to a system and methodology providing automation services in a distributed industrial controller environment. In one aspect of the present invention, a data access service is provided that includes, sending and receiving data to and from a data access service namespace operative in the distributed controller environment. In another aspect of the present invention, an alarming service is provided wherein data values are monitored in a server component according to predetermined conditions configured by a user or other entity. If the data values are determined to be outside of boundaries as defined by the predetermined conditions, an alarm can be communicated to a plurality of other components cooperating in the distributed environment.

Abstract: A production loss tracking system for a manufacturing system includes a collection module, an event module, and a report module. The collection module collects a processing status from a plurality of processing stations. The event module forecasts an upstream production loss event for a first of the processing stations that is upstream from a second of the processing stations that experienced a production loss event when the processing status indicates the production loss event. The event module forecasts a downstream production loss event for a third of the processing stations that is downstream from the second of the processing stations that experienced the production loss event when the processing status indicates the production loss event. The report module communicates with the event module and generates a report indicating the upstream production loss event, the downstream production loss event, and the production loss event.

Abstract: The present invention relates to an alarm management system for acquiring message data for alarms issued from a process and analyzing alarm behaviors. The alarm management system of the present invention selects unnecessary alarms from the message data for alarms and prevents alarms from being issued according to the results of alarm selection. Consequently, the system eliminates the need for engineers who have professional skills and experience, thereby making it possible to precisely select unnecessary alarms.

Abstract: The present invention provides for monitoring the health of a system. In one embodiment, a method includes storing benchmark data in a memory, storing a second plurality of system data indicative of system conditions during system operations, determining from the second plurality of system data that the system was operating at a steady state capacity level during at least one sample window of the system operations, associating the steady state capacity level of the at least one sample window with the benchmark data, retrieving first health data for parameters associated with a first health condition from the first plurality of system data, retrieving second health data for parameters associated with the first health condition from the second plurality of system data that were obtained during the at least one sample window, comparing the health data and determining if the second health data is indicative of a health condition.

Abstract: A process device is configured for coupling to a two wire process control loop. Loop current output circuitry is configured to apply an output current to the two wire process control loop. Loop current verification circuitry is coupled to the two wire process control loop and configured to detect errors in the applied output current. At least a portion of the loop current verification circuitry is independent from the loop current output circuitry.

Abstract: A programming system includes a graphical data entry user interface for a plurality of sequential steps displayed to a user on a monitor. The user selects outputs to be activated for each of the sequential steps and any inputs to be monitored or timer to be enabled for the sequential steps. The inputs, outputs, and timer enable commands, and timer values identified by the user are converted into data tables each having a plurality of data elements. Each data element corresponds to one of the sequential steps. A programmable logic controller directs a process by reading the data elements corresponding to a sequential step and, for that sequential step, activating the outputs identified by the output data element, monitoring any inputs identified by the input control data element, and enabling a timer for a selected time period if identified in the input control data element.

Abstract: A method of protecting a rotating device, loaded by temperature of a machine tool with one temperature sensor on that device and a temperature bloc, comprising the steps of inputting specific parameters in the temperature bloc, estimating a value for the device temperature increase caused by the activity of the device and measuring the temperature of the device.

Abstract: Methods and apparatus, including computer program products, for processing, at a sensor node within a sensor network, a set of sensor readings to determine whether an event has occurred, the set of sensor readings including one or more sensor readings for corresponding environmental conditions. The processing includes determining whether a sensor reading exceeds its corresponding threshold value for an environmental condition, and if so, comparing the set of sensor readings with a history log file to determine whether a false alarm event has occurred. The history log file includes one or more sets of historic sensor readings for corresponding environmental conditions, each set being associated with an environmental situation.

Abstract: A system comprising a housing, an electrical bus, a connector module for connecting the electrical bus to a power source, a battery module so as to provide power to the electrical bus when the power source is not supplying power to the electrical bus, a sensor module for monitoring temperature and utility power status with respect to the space and detecting an alarm condition, a user interface module for permitting a user to (i) store at least one telephone number, and (ii) store the current location of the system, and a cellular telephone module configured to (i) place a cellular telephone call to a stored telephone number when the alarm condition is detected by a sensor, and (ii) advise the call recipient of the current location of the system.

Abstract: An automated method and system that uses a Web service to make real-time production status available to customers from a manufacturing environment. Each time Work in Process (WIP) data is updated from manufacturing execution systems to a central database, a database trigger checks the alert conditions. These conditions are automatically compared to the WIP data to see if the user-defined conditions have been met. If so, a function is called which automatically sends an alert to the customer via the internet and either e-mail, pager, or mobile phone.

Abstract: A method for tracking and reporting traffic activity on a web site first comprises storing a web page on a first server coupled to a network. When the web page is requested from a visitor computer, the visitor computer is selected (or not selected) for inclusion within a sample group, where the sample group is only a subset of the total traffic to the web site. A selection indicator is stored on the visitor computer associated with this selection. Data mining code within the web site is operated or not operated depending upon the value of the selection indicator. The data mining code is operated, and the activity of the visitor computer on the web site consequently tracked only if the visitor computer is selected as a member within the sample group, otherwise the data mining code is not operated and no traffic activity is generated.

Abstract: A system for detecting abnormal situations associated with a reactor in a process plant receives statistical data associated with pressure within a reactor vessel. For example, a pressure sensor device disposed at least partially within the reactor vessel may generate the statistical data based on a pressure signal. The statistical data is analyzed to detect whether one or more abnormal situations associated with an agitator of the reactor exist. For example, the statistical data may be analyzed to detect whether the agitator is no longer turning, is turning at a rate that is different than expected, is out of balance, is broken, etc. If an abnormal situation is detected, an indicator of the abnormal situation may be generated.

Abstract: A transactional data communications system and method communicates information within an enterprise having a process control system and a plurality of information technology systems that are communicatively coupled to the process control system via a web services interface and a transactional information server. The system and method generates transactional process control information and formats the transactional process control information based on an extensible markup language input schema to form formatted transactional process control information. The system and method sends the formatted transactional process control information to the transactional information server via the web services interface and maps the formatted transactional process control information to an extensible markup language output schema associated with one of the plurality of information technology systems to form mapped transactional process control information.

Abstract: A system and method for continuous online safety and reliability monitoring is disclosed. The method includes the steps of obtaining operating information about at least one of a plurality of instrumented function components, which are part of an instrumented function, and determining a probability of failure on demand for the instrumented function based on the operating information. In variations, instantaneous probability of failure on demand, online mean time to failure (MTTF), and online safety integrity level (SIL) are also calculated for an instrumented function. In other variations of the invention, alarms are reported to an operator based on the variance indicating the probability of failure on demand for the instrumented function is too high. In yet further variations, the system allows a user to predict probability of failure on demand values into the future based on hypothetical and/or future planned test times.

Abstract: A voter function block, which can be integrated into a function block diagram programming environment in a process plant control or safety system, implements voter logic in conjunction with providing operational and maintenance overrides which may be set to override individual inputs to the voter function block as well as to override the output of the voter function block. The voter function block, which is easy to create, use, test, debug and document, includes one or input limit detection units which detect if a particular redundant input has reached a specified limit indicating a condition within the process plant, an override unit that may be set by a user to override the consideration of that input in the voting function, a voting logic entity that determines if a trip condition exists based on the values of the valid or non-inhibited inputs, and an inhibit block that may used to override the output of the voter logic block during, for example, a startup or other operational condition.

Abstract: Systems and methods for providing alarming indications and troubleshooting indications and actions in connection with a web converting manufacturing process such as that used for manufacturing disposable absorbent garments. Some of the disclosed embodiments include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

Abstract: A safety network system is constructed by connecting a safety PLC to a safety slave through a safety network. The safety slave obtains safety input informations from a plurality of safety devices connected thereto and transmits information based on the plurality of safety input informations in response to a request from the safety PLC. At this time, the safety slave determines whether or not a safety condition is satisfied based on the plurality of safety input informations, includes two notification modes, that is, a result notification mode in which a result of determination of safety determined by the above determination is transmitted and a detailed information mode in which the plurality of safety input informations are transmitted as they are as aggregated data, and returns a safety response in any of the modes according to a command from the safety PLC.

Abstract: A method for programming a programmable logic controller (PLC) is disclosed. The PLC may be used to control devices of a secured facility, such as a detention center, jail, or prison. The disclosed method may include creating a spreadsheet including information relating to devices and functions of a system to be controlled by the PLC, such as the number and type of door locks and the functionality of the door locks. The method may further include analyzing the spreadsheet to detect errors in the information stored in the spreadsheet. The method may further includes writing PLC logic to control the system based in the information in the spreadsheet.

Abstract: An alarm display and interface system method for use in a process control system enhances device alarm messages to enable the integrated display device alarms with process alarms. The system and method receives a device alarm message from a field device and the device alarm message has a first set of message fields including a first set of device information. The system and method appends a second set of message fields containing a second set of device information associated with the field device to the device alarm message based on the first set of device information to form an enhanced device alarm message and selects a device alarm table based on the second set of device information within the enhanced device alarm message. The system and method maps the first set of device information within the enhanced device alarm message to the selected device alarm table to identify a set of information fields containing displayable alarm information and displays a portion of the displayable alarm information.

Abstract: A terminal table unit is associated with an output apparatus such as valves and solenoids and an input apparatus such as switches and includes not only a main body with a control device and a memory device but also a cassette with a memory medium that is detachably attached to the main body. The control device receives input data from the input apparatus for controlling the output apparatus and drives the output apparatus according to the received input data. The received input data are temporarily stored in the memory device in specified units. When the input data are found to include abnormal data, the control device causes data stored in the memory device to be transferred to the memory medium of the cassette such that the memory cassette can be removed and the abnormal data stored on the memory medium can be analyzed elsewhere.

Abstract: A method and apparatus for providing early fault detection and alert generation in a multi-parameter process is provided. The method comprises defining a multi-dimensional space, each dimension representing a parameter of the process; applying an analysis of the process to the space in order to define regions of high and low probability of occurrence; measuring and mapping parameter values onto the space; and generating an alert whenever a parameter value is mapped into a region of low probability. The method and apparatus are also useful for identifying the cause of faults, adjusting the process to avoid faults and predicting a process-specific maintenance schedule.

Abstract: Distributed control systems and methods. An embodiment of distributed control system may comprise at least first and second nodes operatively associated with one another, the first node issuing a signal to at least the second node in response to an event. A load controlled by the second node, and a distributed controller provided at the second node. The distributed controller executing at least one script corresponding to the signal to control the load.

Abstract: A control system for a bulk material baler embodied in a machine readable data structure and including an instruction to a moveable guide track to move from a removed position to a closed position to create a guide track loop around a volume of bulk material to be baled while that bulk material is under compression and also including in instruction to a bale strap feed drive to feed a pre-determined length of strapping around the guide track loop, and including an instruction to a cutter to cut the end of the bale strap and including an instruction to a strap fastener to fasten together the ends of the bale strap and including an instruction to remove the moveable guide track section from around the bale and an instruction to release compression and an instruction to eject a bound bale.

Abstract: An embodiment of the present invention uses an on-board microcontroller of a household appliance to receive signals from a directionless encoder attached to a knob for receiving user input and processing the signals from the direction encoder according to a control algorithm. The microcontroller may increase the output to an electric heating element on the appliance based on a variety of criteria, including either direction of rotation, current heating element setting, or a change in directional rotation. Alternatively, or in addition, the microcontroller may provide various types of graduate visual or aural feedback to the user regarding the output provided by the microcontroller.

Abstract: A sequence circuit display method for an injection molding machine which enables a sequence circuit corresponding to an operating step to be quickly displayed and enables the connection states of contacts, coils, etc. in a sequence circuit to be easily grasped when obtaining a grasp of the sequence circuit, comprising selectively inputting an operating step name in an injection molding machine from an input device to thereby display a sequence circuit including contacts, coils, etc. corresponding to the selected input operating step as a ladder diagram on a display device; comprising displaying a sequence circuit of an injection molding machine as a ladder diagram on a display device and selectively inputting one of the contacts, coils, etc. in the ladder diagram to thereby display a sequence circuit including contacts, coils, etc. corresponding to the selected input contact, coil, etc. as a ladder diagram on the display device; etc.

Abstract: The safe PLC1 and the safe slaves 2 are connected with each other via the safe network 3. The safe PLC has the function of transmitting a request of safety information by broadcast message to the safe slaves. The safe slaves are each provided with a safety information transmission function for transmitting safety information indicative of whether the safe slave is in a safe condition or not; and a changing function for changing a priority of a transmission frame which carries the safety information. As a result, when the safe slaves send back safe responses at once in response to the broadcast message, safety information (danger) with a higher priority is transmitted ahead of others to the safe PLC.

Abstract: A system for monitoring the condition of a packaging machine during operation and diagnosing potential problems in the performance of the machine. The system comprises an input device, an output device and a processing unit that supports a user interface presented by the output device. The processing unit is arranged to permit a user, when in use, to input via the user interface a number of pre-determined parameters to measure one or more elements or assemblies in the machine, to receive information from one or more sensors measuring the element or assembly and to analyse the information with the parameter to render via the output device a signal.

Abstract: A method and apparatus to perform an automatic diagnosis for the poor performance of a control loop, and to determine whether or not the malfunctioning is caused principally by a poor adjustment of the controller tuning parameters. The method makes use of the fact that a poorly tuned control loop amplifies disturbances in a narrow frequency range around the so-called resonant frequency. The method comprises measuring an error in a control loop over time to determine a power spectral density of the error, determining a best fit analytical function describing the power spectral density and measuring a diagnostic value from a difference between the best fit analytical function and the power spectral density of the error.

Abstract: A method for controlling at least one device (12) with a control system (10). The devices (12) can provide input signals (16) to the control system (10), receive output signals (14) from the control system (10) to operate the device (12), or a combination of both. When the device (12) is first connected to the control system (10), the control system (10) identifies the device (12) and selects a set of parameters and instructions from a database (18). An operator can then select values for the parameters. The parameters and instructions then define the operation of the device (12). Each controlled device (12) acts autonomously with respect to other devices (12). When the device (12) is actuated through a series of operations, the method determines the next operation of the device (12), after the device (12) has been turned off and back on again.

Abstract: An operating method for a fault detection of a semiconductor process and a diagnostic system for fault detection in a semiconductor process are described. By using the method and the diagnostic system, the real-time process parameters collected during the process is performed by the tool become meaningful and are correlated with the historic process performance data obtained by the post process metrology process. Moreover, the method and the diagnostic system further provide an alarm index for the process performed on the tool to actually reflect the process environment during the process is performed after correlating the real-time process parameters and the historic process performance data. With referring to the alarm index, the current process performance under the real-time process parameters in the tool can be accurately diagnosed.

Abstract: Even when a power switch is turned off, the controller of an injection molding machine does not shut off a power supply immediately. The controller determines whether the present state of the injection molding machine is a previously-set confirmation-requiring state, such as a lockup state of a mold clamping unit using a toggle link mechanism, or a nozzle touch state of an injection unit. When the present state is not the confirmation-requiring state, the controller shuts off the power supply. When the present state is the confirmation-requiring state, the controller displays on a display screen a confirmation window for confirmation of power shut off. The controller shuts off the power supply in accordance with a shut-off operation performed on the basis of the confirmation window.

Abstract: An impending fault of a component operated within a closed-loop control system can be detected. The close-loop control system is disabled. An actuator of the closed-loop control system is operated at one or more test values. A sensor reading of the actuator is taken while that actuator is operated at the one or more test values. A warning is generated if an impending fault condition is detected. An impending fault condition may be detected if the component operates at a value exceeding a maximum defined operating value, if the component operates at a value below a minimum defined operating value, or if an operating range that is narrower than a defined full operating range for the component is detected.

Abstract: A system and method is disclosed for controlling concentration of a component chemical product in a chemical solution. The chemical solution is formed in a solution tank by combining the component chemical product with water. The component chemical product is dispensed to the solution tank by a chemical dispenser that is controlled by measured conductivity readings of the chemical solution taken in the solution tank. The conductivity readings are analyzed against a conductivity setpoint to determine whether the component chemical product should be added to the chemical solution. A conductivity offset is determined and applied to the analysis thereby taking into consideration any conductivity that may be attributable to constituents of the chemical solution other than the component chemical product. Such constituents include soil washed from the articles and the water used to form the chemical solution.

Abstract: A handheld medication dosage calculator (100) and method for comparing an inputted, ordered medication dosage with a known medication dosage range in a database including an input device for inputting a desired drug name, indicating whether the drug is for a child or an adult, an amount of the drugs that are ordered, the body weight or body surface of the patient, an amount of drug available in standard packaging, and the available volume associated with the available drug and a computing mechanism for determining the dosage of the drug to be delivered. The handheld medication dosage calculator (100) provides warnings when the inputted amount of drug exceeds the dose range limits or is incorrect. The handheld medication dosage calculator (100) converts an inputted drug unit of measure into a desired unit of measure. The handheld medication dosage calculator (100) lists generic drug names, trademarked product names, drug classifications and cautionary drug warning information.

Abstract: An architecture for an automation system is disclosed that includes look-up services, a soft-state store, and a publication/subscription eventing component. The look-up services maintain a database of a number of devices to be controlled and monitored, and a database of a number of device objects corresponding to the devices. The services can be divided into attribute-based and name-based services. The soft-state store manages variables regarding the devices and the device objects, including heartbeats. The eventing component enables subscriptions to events related to changes in the variables. The architecture can include management daemons, such as a monitoring daemon that detects problems with power line devices.

Abstract: An event notification system is described. The system comprises a computer having a CPU and memory and which executes an operating system operative to manage computer programs and wherein the programs generate events, a notification controller connected to the computer and operative to detect the generated events, a notification transceiver communicatively connected to the notification controller and capable of transmitting a message containing data on the event, and a portable transceiver including a notifier for receiving the message.

Abstract: A computer is connected to a system formed by combining a robot with a peripheral device (such as a welder). The computer receives robot mechanical unit motion position information supplied from a robot controller and command information to be outputted to the peripheral device, and displays motions of the robot mechanical unit and the peripheral device on its display screen in an animation form.

Abstract: An apparatus and system are disclosed for the real-time monitoring and control of field assets. The monitoring device, operable to couple to a field asset, may be designed to leverage one or more technologies included in the field asset or as a stand-alone unit and is preferably operable to detect one or more error conditions thereon. The error conditions may be detected either as they occur or during testing intervals. Once an error condition is detected, the monitoring device may initiate one or more corrective sequences to resolve the error condition or, alternatively, the monitoring device may notify a network operations center via a wireless network. Accessing a network operations center from an Internet-enabled remote device, a user may view status information for one or more field assets, issue commands to correct error conditions as well as perform other functions.

Abstract: Failure prediction for complex processes is performed utilizing one or more nonlinear regression models to relate operational variable values measured at two or more times to predicted process metric values and maintenance variable values.

Abstract: Safety level error detection comparable to that provided by redundant wired safety relays is obtained on a backplane of a programmable logic controller or the like by a combination of error detection methods that in sum provide the requisite level of error detection required without necessitating a particular hardware requirement or duplicative message transmissions.

Abstract: According to one embodiment of the invention, a computerized method for managing time standards includes receiving a set of work instructions associated with the manufacturing of a part and receiving an association of each work instruction of the set of work instructions with one or more of a plurality of time standard templates. Each time standard template includes a task associated with the manufacturing of the part at a task center, one or more variables associated with the task, one or more variables associated with the task center, and an algorithm operable to determine a time value associated with the task. The time value represents a time period to complete the task. The computerized method further includes receiving a change to one of the variables associated with the task, generating a plurality of time standards associated with the work instructions, and storing the time standards in a database.

Abstract: A system and method is disclosed for controlling chemical dispense operations based on a conductivity offset determined for a chemical solution. The chemical dispense operations are performed by or in conjunction with operation of a utility device, such as a warewashing machine. The chemical solution is formed in a solution tank device by combining water with at least one component chemical product. The conductivity offset, which is the conductivity of the water, is used to normalize the conductivity estimated for the chemical solution relative to the component chemical product in the solution. During various points in time during operation of the utility device, the normalized conductivity is compared to a conductivity setpoint, and if the normalized conductivity falls below the conductivity setpoint, a specified volume of the component chemical product is supplied to the solution tank.

Abstract: An object of the present invention is to quickly and accurately detect disorder or abnormality of a process state which occurs in a plant and to appropriately perform an operation for normalizing disorder or abnormality of the process without depending on experience or skill of an operator. A control system of the plant is divided into groups having relation, such as, the plant, processes, or steps, and a monitor picture is created for each of them. When an alarm is raised, the alarm is displayed on a picture associated with the alarm. A guidance picture for supporting how to deal with the alarm is provided.

Abstract: A module for controlling a drive is described. The module contains a terminal for connecting to a control system for operating tasks and a control system for safety tasks. Commands from the control system for safety tasks have priority over commands from the control system for operating tasks. A microprocessor is provided for processing the commands and is coupled to the terminal. A logic circuit is provided for prioritizing the commands from the control system for safety tasks, the logic circuit is connected to the microprocessor. At least one output is coupled to the microprocessor and/or the logic circuit. An interface is provided for connecting to the control system for operating tasks or a diagnostic device, the interface is connected to the microprocessor. A memory is provided for storing the commands and replies, the memory is connected to the microprocessor.

Abstract: An alarm mechanism is provided. The alarm mechanism includes a hardware component and a software component. The hardware component includes first and second registers. The first register is adapted to store a value that indicates a change in state of at least one alarm and the second register is adapted to store current states of each of the at least one alarm. The software component is responsive to interrupt requests from the hardware component and is adapted to read the first and second registers.

Abstract: A management system for managing information of monitor wafers stored in a storage center includes an operation rule module for determining the next manufacturing process for each of the monitor wafers according to its wafer number and wafer condition, an information update module for updating the information of the monitor wafers in a database according to the results made by the operation rule module, an inventory module for computing an inventory quantity of the monitor wafers according to the wafer numbers and the wafer conditions of the monitor wafers, a warning module for checking whether the inventory quantity of the monitor wafers is less than the quantity of the safety stock or not and sending a warning message when the inventory quantity of the monitor wafers is less than the quantity of the safety stock, and a display module for showing the wafer conditions and the inventory quantity of the monitor wafers.

Abstract: An electrical control system is disclosed for controlling a plurality of variable transmittance windows. The electrical control system of the present invention comprises a master control circuit for supplying control signals representing transmittance levels for the variable transmission windows, and a plurality of window control circuits coupled to each of the master control circuit. Because the window control circuits can sense abnormal load conditions in the variable transmission windows, the system further includes an interface to a security system to inform of a potential intrusion. Each window control circuit controls the transmittance of at least one of the variable transmission windows in response to control signals received from the master control circuit.