Abstract: A process for performing real-time cascade control for use in controllers. An adaptive process module uses an algorithm to set parameters during system operation to attain the best possible control performance, while providing an easier-to-use system for the user. The algorithm uses a novel adaptive technique to intelligently adjust the minimum and maximum allowable controlled-variable set point limits, under varying load conditions.

Abstract: A diagnostic test unit for deterministically measuring one or more parameters, such as dead band, dead time, response time, gain, or overshoot, of a process control device that is connected in a process control loop during operation of a process includes a switch controller, a signal generator, a switch, a response accumulator mechanism, and an analyzer mechanism. The switch controller monitors a process signal during operation of the process to determine whether the process signal is substantially stable. In the event that the process signal is substantially stable, the switch replaces a control signal with a diagnostic test signal generated by the signal generator. The response accumulator is in communication with the process control loop to obtain an indication of the response of the process control device to the diagnostic test signal. The analyzer unit then determines the device parameter from the test signal and the response indication.

Abstract: The painting equipment controller controls automotive painting equipment so that desired painting attributes can be achieved. A database is used for storing mathematical models which interrelate painting factors with painting responses. The painting factors include the control settings of the painting equipment. The painting responses include such painting attributes as the appearance of the paint and application attributes of the paint. A database engine determines the values for the painting responses based upon the model and upon initially selected painting factor values. A cooptimizer uses the output of database engine to determine a second set of values for the painting factors which achieve the desired painting attributes. Thereupon, the painting equipment is controlled based upon the painting factor values as determined by the cooptimizer.

Abstract: A device in a process control system includes a memory for storing a series of sensed process variables and command outputs representative of a learned process cycle. Comparison circuitry compares recent process information to learned process information stored in the memory and responsively provides a validity output signal. A method includes learning a cycle of a process to provide learned process information which comprises stored process variables and stored control signals over a time period, measuring a process variable in the process and responsively calculating the control output, storing the process variable in the control output to provide recent process information, and comparing the recent process information to the learned process information and responsively providing a validity output signal.