Abstract: The present invention is a block oriented control system that allows interoperability between devices made by different manufacturers. A block oriented control system is a system which includes a plurality of field devices incorporating a physical layer, communication stack, and user layer, with the field devices being connected by a transmission medium, such as a bus. The physical layer receives signals from the bus and translates the signals into a message for the communications stack, and receives messages from the communications stack and translates the messages into signals for the bus. The communication stack controls the communications between devices operating in the control system. The user layer is a block oriented approach to the system's control functions, and includes function blocks and system management. The function blocks are standardized encapsulations of control functions, such as analog input or proportional/derivative.

Abstract: A system and method for adaptively designing self-tuning controllers, specifically PID controllers for process control systems. The method is based on a model-parameter interpolation, according to which a candidate process model is defined by a predetermined, limited set of models. Each of the models is characterized by a plurality of parameters, and, for each model, each of the parameters has a respective value that is selected from a set of predetermined initialization values corresponding to the parameter. Evaluation of each of the models includes computation of a model squared error and computation of a Norm that is derived from the model square errors calculated for the models. The Norm value is assigned to every parameter value represented in the model that is represented in an evaluation scan. As repeated evaluations of models are conducted, an accumulated Norm is calculated for each parameter value.

Abstract: A diagnostic tool automatically collects and stores data indicative of a variability parameter, a mode parameter, a status parameter and a limit parameter associated with each of the different devices, loops or function blocks within a process control system, processes the collected data to determine which devices, loops or function blocks have problems that result in reduced performance of the process control system, displays a list of detected problems to an operator and then suggests the use of other, more specific diagnostic tools to further pinpoint or correct the problems. When the diagnostic tool recommends and executes a data intensive application as the further diagnostic tool, it automatically configures a controller of the process control network to collect the data needed for such a tool.

Abstract: An adaptive process controller drives a process variable to be substantially equivalent to a set point and adapts the controller gain, the controller reset, and/or the controller rate, based on model free adaptation. The adaptive controller combines a controller gain computed from an oscillation index with a controller gain computed from a steady state estimate and that adapts the controller reset/rate by forcing the ratio of two of the controller proportional, integral or derivative terms to be equal to a predetermined value.

Abstract: A modifier function block adapted for use in process control routine includes a series of processor implementable instructions that conditionally enhance or modify the functionality of a base function block associated with the process control routine. The base function block includes a resettable branching point located within a set instructions used to perform a process control related operation. The branching point of the base function block has a pointer which, when set to a first value, causes another of the set of instructions within the base function block to be executed (to thereby bypass the execution of the modifier function block), and which, when set to a second value, causes the series of instructions within the modifier function block to be executed (to thereby alter the functionality of the base function block).

Abstract: An advanced control block that implements multiple-input/multiple-output control, such as model predictive control, within a process control system is initiated by creating an initial control block having generic control logic and desired control inputs and control outputs communicatively connected to process outputs and process inputs within a process control routine. A waveform generator within the control block systematically upsets each of the process inputs via the control block outputs using excitation waveforms designed for use in developing a process model. At the same time, a data collection routine collects data indicating the response of each of the process outputs to the waveforms delivered at each of the process inputs. After sufficient data has been collected, a process modeling routine generates a process model from the collected data and a control logic parameter creation routine creates control logic parameters for the control logic from the process model.

Abstract: An auto-tuner for use in tuning a control element in a process control network having distributed control functions includes a first tuning element located in the field device in which the control element is operating and a second tuning element located in a different device that communicates with the first device via a communication network. The first tuning element controls the operation of the control element during the dynamic data capture phase of an auto-tuning procedure, collects data during this phase of the auto-tuning procedure and determines one or more process characteristics from the collected data. The first tuning element then communicates the determined process characteristics to the second tuning element via the communication network.

Abstract: A diagnostic tool automatically collects and stores data indicative of a variability parameter, a mode parameter, a status parameter and a limit parameter associated with each of the different devices, loops or function blocks within a process control system, processes the collected data to determine which devices, loops or function blocks have problems that result in reduced performance of the process control system, displays a list of detected problems to an operator and then suggests the use of other, more specific diagnostic tools to further pinpoint or correct the problems. When the diagnostic tool recommends and executes a data intensive application as the further diagnostic tool, it automatically configures a controller of the process control network to collect the data needed for such a tool.

Abstract: A diagnostic tool automatically collects and stores data indicative of a variability parameter, a mode parameter, a status parameter and a limit parameter associated with each of the different devices, loops or function blocks within a process control system, processes the collected data to determine which devices, loops or function blocks have problems that result in reduced performance of the process control system, displays a list of detected problems to an operator and then suggests the use of other, more specific diagnostic tools to further pinpoint or correct the problems. When the diagnostic tool recommends and executes a data intensive application as the further diagnostic tool, it automatically configures a controller of the process control network to collect the data needed for such a tool.

Abstract: A recursive on-line wavelet data compression technique which may be used in, for example, a process control network, compresses a stream of data points on-line or in real-time (e.g., as the data arrives or is generated) without requiring the storage of a large amount of uncompressed data. The data compression system includes a data receiver that receives the data points in a sequential manner and a compression tree computation device that determines approximation coefficients and detail coefficients of a multi-layer wavelet compression tree from the received data points. The compression tree computation device determines all of the coefficients of the higher level layers of the compression tree that can be determined after the data receiver receives each of the data points to thereby perform on-line or real-time data compression.

Abstract: A control template represents a selected function of a control process for a control environment and being used to generate a plurality of displayable views of the selected function. The template includes process control information such as algorithms and known control parameters of the control process, attribute information for the process environment such as inputs and outputs, at least one conversation set associated with the process control function information for relating specific control parameters of the control process in terms of a selected control template view and control method instructions that use the attribute information and at least one conversation set to form a process control solution. A system creates or modifies the control template.

Abstract: A system and method for automatically tuning a process controller used to control an industrial process, or the like. The controller is removed from closed-loop control of a process under control, and a signal is applied to the process under control to cause the process to undergo controlled self-oscillation. A first portion of the self-oscillation procedure is used to determine a Time Delay characteristic of the process under control, and a subsequent portion of the self-oscillation procedure as used to calculate an Ultimate Gain characteristic and an Ultimate Period characteristic of the process under control. These three characteristics are then used to calculate control parameters which are used to tune the controller. After tuning, the controller is placed back into a closed-loop with the process under control.

Abstract: A processing system utilizing heat recovery has a plurality of digesters in which products such as wood chips may be reacted at high temperature and pressure to form pulp suitable for use in the manufacture of paper. The digesters are fluidly connected to a plurality of heat recovery tanks including a cool liquor tank, a warm liquor tank, and a hot liquor tank. The digesters are also fluidly connected to a displacement tank which periodically supplies fluid to the digesters for the purposes of displacing their contents. The fluid levels within the heat recovery tanks and within the displacement tank are automatically controlled. In processing, predetermined volumes of cool and hot liquor are periodically pumped to each digester as well as automatically determined volumes of warm liquor and displacement fluid.