Enhanced wake activation response speeds for industrial control systems

One embodiment of the present disclosure describes a method executed by a processor. The method includes receiving a signal associated with a process system transitioning from a reduced energy mode to an active mode. The process system includes devices configured to operate based on data acquired by sensors. The method includes determining a difference between a set of actual data acquired by the sensors and a desired operating parameter of the process system. The method includes reducing the difference using a control algorithm based at least in part on a preload value (e.g., a predetermined value representative of data acquired by the sensors) retrieved from a memory device. The method includes determining a set of control signals based in part on the reduced difference and transmitting the set of control signals to the devices, thereby driving a current operating parameter of the process system toward the desired operating parameter.

BACKGROUND

The present disclosure generally relates to controls systems, and more particularly to an industrial control system having enhanced response speeds during a sleep-wake transition period and techniques used to enhance response speeds of the industrial control system.

Many industrial applications utilize industrial control systems, and a wide variety of control system designs are implemented within the industrial control systems. In general, a feedback loop control system is a type of control system design that is widely used in industrial control systems to control a process (e.g., industrial or manufacturing process). A particular problem with existing control systems, and particularly with feedback loop control systems, is the response speed of the industrial control system during a sleep-wake transition period. For example, certain process systems transition between a “sleep” or energy saving mode and a “wake” or active mode based on the demand of the process system output. In certain situations, the response speed of the control system may be slow, as the process system transitions from the sleep mode to the wake mode. Accordingly, it may be beneficial to improve the response speed of the control system during the sleep-wake transition period to improve the efficiency and output of the process system as it transitions to a wake or active mode.

BRIEF DESCRIPTION

In an embodiment, a method is provided. The method includes receiving, via a processor, a signal associated with a process system transitioning from a reduced energy mode to an active mode. The process system includes one or more devices configured to operate based on data acquired by one or more sensors of the process system. The method also includes determining, via the processor, a first difference between a first set of actual data acquired by the sensors and a desired operating parameter of the process system. The method also includes reducing, via the processor, the first difference using a control algorithm based at least in part on a preload value retrieved from a memory device. The preload value is a predetermined value representing data acquired by the sensors, and the predetermined value is different from the first set of actual data. The method also includes determining, via the processor, a first set of control signals based at least in part on the first reduced difference. The first set of control signals are associated with one or more output parameters for the one or more devices. The method also includes transmitting, via the processor, the first set of control signals to the one or more devices, thereby driving a current operating parameter of the process system toward the desired operating parameter.

In another embodiment, a system is provided. The system includes a process system and a controller coupled to the process system. The process system is configured to transmit a signal associated with the process system transitioning from a reduced energy mode to an active mode. The process system comprises one or more devices configured to operate based on data acquired by one or more sensors of the process system. The controller is configured to provide one or more output parameters for the one or more devices. The controller is also configured to receive the signal from the process system, determine a difference between a set of actual data acquired by the sensors and a desired operating parameter of the process system, and minimize the difference with the control algorithm based at least in part on a preload value retrieved from a memory device. The preload value is a predetermined value representing historical data that may be acquired by the sensors. The controller is also configured to determine one or more control signals associated with the output parameters based at least in part on the reduced difference and transmit the one or more control signals to the process system. The one or more control signals are configured to adjust the one or more output parameters for the one or more devices closer to the desired operating parameter of the process system.

In another embodiment, a tangible, non-transitory, computer readable medium is provided. The tangible, non-transitory, computer readable medium includes machine-readable instructions to receive a signal from a process system associated with the process system transitioning from a reduced energy mode to an active mode. The process system includes one or more devices configured to operate based on data acquired by one or more sensors of the process system. The machine-readable instructions further determine a difference based on a set of actual data acquired by the sensors and a desired operating parameter of the process system and determine a reduced difference based at least in part on a preload value retrieved from a memory device. The preload value is a predetermined value representing historical data that may be acquired by the sensors. The machine-readable instructions further determine one or more control signals associated with output parameters for the one or more devices based at least in part on the reduced difference and transmit the one or more control signals to the process system. The one or more control signals are configured to adjust the one or more output parameters for the one or more devices closer to the desired operating parameter of the process system.

DETAILED DESCRIPTION

While the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and tables and have been described in detail herein. However, it should be understood that the embodiments are not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Further, although individual embodiments are discussed herein to simplify explanation, the disclosure is intended to cover all combinations of these embodiments.

Embodiments of the present disclosure generally relate to industrial control systems that may monitor and/or control a process system. The process system may be any type of industrial process system and/or any type of industrial process plant (e.g., oil and gas, refining, chemical, pharmaceutical, food and beverage, water and/or wastewater, paper, utility power or water, mining, metals, etc.) having one or more sensing devices and one or more control devices. Specifically, systems and methods of the present disclosure generally relate to improving the performance of an industrial control system by enhancing the response speed of the process system when transitioning the process system from a sleep mode to a wake mode. As noted above, a process system may often transition between a sleep mode and an active mode depending on the demand for the output provided by the process system. For example, the process system may enter a sleep mode (e.g., reduced activity mode, energy saving mode) when demand for the process output is below a sleep threshold, and the process system may transition to a wake mode (e.g., an active mode) when demand for the process output is above a wake threshold. In certain situations, the industrial control system, which may be used to control the process system based on sensed feedback from the process system, may also enter a sleep mode when the process system enters the sleep mode and a wake mode when the process system enters the wake mode. As further described in detail below, it may be beneficial to improve the response speed of the process system when the process system transitions from the sleep to the wake mode to improve the efficiency and output of the process system. Specifically, it may be beneficial to manipulate the inputs of the industrial control system to improve the response time of the process system (and/or the industrial control system) when transitioning from a sleep mode to a wake mode.

In certain embodiments, the industrial control system may monitor and/or control the process system via a feedback loop. For example, in certain situations, a feedback loop may provide data from the process system that may be used by the industrial control system to manipulate one or more controlled variables of the process system to achieve desired levels or outputs (e.g., desired target values or ranges, desired setpoint value, etc.) of the process system. In certain embodiments, the industrial control system may employ a controller to determine adjustments to controlled variables of the process system based on the feedback data from the process system. For example, the controller may be a proportional-integral-derivative controller (e.g., PID controller), a proportional-integral controller, a proportional-derivative controller, a integral controller, a proportional controller, or so forth. With this in mind, the PID controller may calculate and minimize a difference (e.g., error) between a measured process variable of the process system (e.g., feedback) and the desired process system levels (e.g., desired target values or ranges, the desired setpoint value, etc.), such as the desired process system output levels. For example, the PID controller may minimize this difference by adjusting or manipulating a controlled variable of the process system. That is, the PID controller may determine anticipated trajectories or future values for measured and controlled variables of the process system based upon feedback data from the process system. The PID controller may then adjust the controlled variables of process system to obtain desired levels of these predicted variable trajectories. It should be noted, however, that any type of controller or combination of controllers suitable for controlling and/or regulating a feedback loop may be implemented with the industrial control system.

When transitioning from a sleep mode to an active mode, the industrial control system may receive a command to activate the process system to achieve a desired output. As such, in one embodiment, the PID controller may increase the output of the process system, receive feedback regarding the output of the process system, and adjust the controlled variables of the process system based on a difference between the feedback value and the desired output value. In this manner, the PID controller may incrementally increase the output of the process system until the feedback data from the process system indicates that the desired output is achieved. In certain embodiments, enhancing the speed at which the process system achieves the desired output during the sleep-wake transition period may involve preloading feedback data that the PID controller may use to adjust the controlled variables of the process system. For example, in certain embodiments, the PID controller may use one or more preload values to manipulate sensed feedback and thus adjust one or more controlled variables of the process system to cause the process system to provide an output that may be closer to the desired output. After the process system adjusts its controlled variables based on the commands from the PID controller, the PID controller may then receive real feedback data from the process system and further adjust the controlled variables of the process system to achieve the desired output. Since the controlled variables currently being used by the process system do not correspond to initial control variables commonly present when initially exiting the sleep mode, the feedback data provided to the PID controller may be closer to the desired output as compared to initializing the process system from its sleep mode. As a result, the process system may exit its sleep mode and achieve the desired setpoint more quickly.

With the forgoing in mind,FIG. 1is a schematic block diagram of a process system10that is at least partially monitored and/or regulated by a control system12. The process system10may be any type of industrial process system and/or any type of industrial process plant (e.g., oil and gas, refining, chemical, pharmaceutical, food and beverage, water and/or wastewater, paper, utility power or water, mining, metals, etc.). For example, in certain embodiments, the process system10may be a manufacturing process, a steady state or batch process, a chemical process, a material handling process, an engine or other energy utilizing process, an energy production process, a utility distribution process, and so forth. Indeed, in complex processes found throughout various industries, the process system10may receive various types of feed stocks, electrical energy, fuels, utilities, parts, assemblies and sub-assemblies, and the like, to generate products, semi-finished products, assemblies, manufacturing products, by products, and the like. The control system12may dynamically monitor and/or control various operations of the process system10, including control of the supply, the production, and the output of the process system10. For the purposes of the disclosure, a water distribution process system may be utilized as an exemplary embodiment of the process system10to describe one or more embodiments of the present disclosure disclosed inFIGS. 1-4. However, it should be noted the embodiments described herein are not limited to this exemplary embodiment, and may be utilized in a wide variety of processes and industries, as noted above.

In the illustrated embodiment, the process system10includes a number of input devices14that may detect various operational parameters of the process system10. For example, the input devices14may be sensors that detect (e.g., measure, sense) current operational parameters of a process variable of the process system10. A process variable of the process system10may be a dynamic feature of the process system10that varies during the operation of the process system10. In general, the input devices14may include various types of sensors, such as measurement devices, motion sensors, transducers, a pressure sensor, a temperature sensor, a level sensor, a flow sensor, and the like, that may produce discrete or analog signals and values representative of the current operating parameters of the process variables. The current operating parameters may include, for example, sensed or measured information related to temperatures, pressures, levels, flows, quantity of inputs or outputs, speeds of production or manufacturing operations, or any other operating parameter that dynamically varies during operation of the process system10. The input devices14commonly produce voltage or current outputs that are representative of sensed feedback and/or the measured data generated by the process variables. The input devices14may communicatively coupled to the control system12, and may provide the sensed feedback and/or the measured data as feedback signals15to the control system12, where the feedback signals are related to the detected conditions of the process system10.

In certain embodiments, based on the sensed feedback and/or the measured data received from the input devices14, the control system12may output one or more control signals17to output devices16. The output devices16may include a variety of control or operational equipment that may control a controlled variable of the process system10. A controlled variable of the process system10may be a dynamic feature of the process system10that regulates the output of the process system10. For example, the controlled variable may be controlled by adjusting an operational parameter of the output devices16, which include various types of electric motors, valves, actuators, pumps, and/or flow control devices that may perform a mechanical action in response to the control signals from the controls system12. Indeed, the control of the controlled variable may be implemented by adjustments to the output devices16, which in turn control the output of the process system10.

In certain embodiments, the process system10may transition between a sleep mode and an active mode depending on the demand for the output produced by the process system10. It should be noted that in some situations, the control system12may regulate when the process system10transitions between the sleep mode and the active mode, or various other operational modes or statuses. Further, in certain situations, the control system12may enter a similar mode as the process system10. For example, based on the sensed feedback provided by the process system10and/or the lack of sensed feedback provided by the process system10, the control system12may enter the sleep or active mode. In certain embodiments, the control system12may transition to a wake mode when a wake activation signal or an initial feedback signal is received.

For example, within a utility distribution system, such as a water distribution system, the water distribution system may transition between a sleep mode or a wake mode depending on the demand for the output of the water distribution system (e.g., water). The water distribution system may include one or more input devices14, such as pressure sensors, flow sensors, temperature sensors, and so forth. Further, the water distribution system may include one or more output devices16, such as water pumps, actuators, flow control devices (e.g., valves, orifice plates, etc.). The input devices14may provide a feedback signal15(or a wake activation signal) to the control system12, where the feedback signals are related to the detected conditions of the water distribution system (e.g., pressure of the water output, flow of the water output, quantity of the water available, etc.). Further, based on the feedback signal and/or a demand for the water output, the control system12may control a water pump to increase/decrease supply to meet the demands. In certain situations, based on the feedback signals, the control system12may determine the status of the process system10(e.g., active mode, sleep mode, etc.).

The control system12may utilize the input devices14and the output devices16to monitor and/or control the process system10. In certain embodiments, the control system12may include an application-specific or general purpose computer, processor, or other programmable device programmed to carryout the functions described herein. In the illustrated embodiment, the control system12includes a processor18. As depicted, the processor18(e.g., processing circuitry) and/or other data processing circuitry may be operably coupled to the memory22to retrieve and execute instructions for monitoring and controlling the process system10. For example, these instructions may be encoded in programs or software that are stored in memory22, which may be an example of a tangible, non-transitory computer-readable medium, and may be accessed and executed by the processor18to allow for the presently disclosed techniques to be performed. Specifically, carrying out the functions described herein via these instructions may help to improve the function of the control system12(e.g., application-specific or general purpose computer, processor, or other programmable device) by improving efficiency and reliability. The memory22may be a mass storage device, a FLASH memory device, removable memory, or any other non-transitory computer-readable medium. Additionally and/or alternatively, the instructions may be stored in an additional suitable article of manufacture that includes at least one tangible, non-transitory computer-readable medium that at least collectively stores these instructions or routines in a manner similar to the memory22as described above. In some situations, one or more processors18may be disposed within and/or operate with the control system12, and each processor18may cooperatively function with each other to control the process system10.

Further, in certain embodiments, the control system12may include a display24and/or various input/output features26(e.g., I/O features26). The display24may be any interactive (e.g., touch screen) or other display, that displays information received from the input devices14(e.g., current operational parameters, sensed feedback and/or measured data, etc.), information related to the output devices16(e.g., positional information of the output devices16, control signals provided to the output devices16, etc.), information related to the control system12(e.g., inputs/outputs received from an operator), information related to the status of the control system12and/or the process system10(e.g., sleep mode, wake mode, etc.). In certain embodiments, the I/O features26may be integral with the control system12, and may receive feedback signals from the input devices14and provide control signals to the output devices16. Further, in certain embodiments, the I/O features26may receive user inputs from an operator for various operational aspects of the control system12and/or the process system10. For example, as further described in detail with respect toFIGS. 2-4, in certain embodiments, the I/O features26may receive a preload value or a setpoint value from the operator, and the control system12may utilize the preload value to enhance the response speeds of the process system10during a sleep-wake transition period of the process system10, as further described below.

In certain embodiments, the input devices14(e.g., sensors) and the output devices16(e.g., actuators, motors, valves, pumps, etc.) may be utilized with a feedback loop28that is monitored and controlled by the control system12to control one or more operational aspects of the process system10. In certain embodiments, the feedback loop28may be used by the industrial control system12to manipulate one or more controlled variables of the process system10to achieve desired levels or outputs (e.g., desired target values or ranges, desired setpoint value, etc.) of the process system10. For example, based on the feedback received from the input devices14, the control system12may generate one or more controls signals to control the output devices16, thereby manipulating the controlled variables of the process system10to achieve desired levels or outputs. Accordingly, the control system12may monitor and control the feedback loop28to dynamically and continuously control aspects and characteristics of the process system10based on sensor feedback and/or measured data obtained from the process system10.

With the forgoing in mind, the disclosed embodiments relate to enhancing the response speeds of the process system10when the process system10transitions from the sleep mode to the wake mode to improve the efficiency and output of the process system10. Specifically, the response speed of the process system10may be improved by utilizing one or more preload values within one or more components of the control system12. The preload values may be utilized by the control system12to manipulate the sensed feedback of the control system12and cause the process system10to provide an output that may be closer to the desired output, as further described in detail below with respect toFIGS. 2-4. Accordingly, the control system12may utilize the preload values to improve the response speed of the process system10(and/or the control system12) as the process system10receives a new demand and transitions from the sleep mode to wake mode to meet the new demand. Further, after manipulating the sensed feedback to improve the response speed of the process system10, the control system12may resume receiving real feedback and further adjusting the controlled variables of the process system10to meet the desired output or demand.

FIG. 2is a schematic block diagram of the feedback control loop28between the process system10and the control system12ofFIG. 1. In particular, the control system12utilizes a preload value23and the feedback control loop28to enhance a response speed of the process system10when the process system10transitions between sleep and active modes, in accordance with embodiments of the present disclosure. As noted above, the process system10and/or the control system12may transition between a sleep mode and an active mode, based on the demand for the output provided by the process system10. The preload value23may be a predetermined value loaded into one or more components of the processor18to initialize the control system12at an initial feedback value when the process system10transitions from a sleep mode to an active mode (and/or detects a new demand). Indeed, the control system12may manipulate the initial sensed feedback received from the process system10with the preload value23, thereby causing the process system10to provide an output that is closer to the desired output. In this manner, the control system12may utilize the preload value23to initialize at a predetermined initial feedback value that is closer to the desired output, and the predetermined initial feedback value may be different than the actual initial feedback value received from the process system10. In this manner, the control system12may increase the accuracy in controlling the output of the process system10when utilizing the preload value23and reduce the possibility of overshooting the desired output of the process system10. Accordingly, the control system12may utilize the preload value23and the feedback control loop28to enhance the response speed (e.g., wake activation response speed) of the process system10during the transition period where the process system10(and/or the control system12) resume active operations after detecting a new demand, as further described in detail below.

As noted above, the control system12may control and/or monitor the process system10with the feedback control loop28. The control system12may include the processor18(e.g., processing circuitry) and/or the memory22(e.g., memory circuitry). In the illustrated embodiment, the control system12is described in the context of a proportional-integral-derivative controller (e.g., PID controller). However, it should be noted that in other embodiments, any type of controller may be utilized, such as any type of controller (e.g., proportional-integral controller, proportional-derivative controller, integral controller, proportional controller, etc.) that may anticipate trajectories or future values for measured and controlled variables based upon prior feedback knowledge. Indeed, any type of controller that may be implemented with the feedback control loop28, the control system12, and/or the process system10to bring the process system10to desired operating parameters or conditions may be utilized. Specifically, in the illustrated embodiment, the control system12may optimize control of the process system12with the feedback control loop28.

In certain embodiments, the feedback control loop28may enable the control system12to iteratively tune the output device control signals32(provided as control signals17) to achieve desired outputs from the process system10based on the input devices feedback34and a setpoint value30. The input devices feedback34may be the sensed feedback and/or measured data detected and received from the process system10via the feedback signals15. The setpoint value30may be the desired operating parameters, values, or outputs of the process system10, which may be derived through operator input and/or from historical operating parameters. Accordingly, based on the input devices feedback34and the setpoint value30, an adder36may calculate a difference38between the input devices feedback34and the setpoint value30. Specifically, the difference38is represented as an error value40between the input devices feedback34and the setpoint value30. The control system12may minimize the error value40by tuning the control signals17to adjust the operating parameters of the process system10. Minimizing or reducing the error value40may result in the output of the process system10beginning to achieve the desired output or the desired setpoint value30.

For example, in certain embodiments, the control system12may be configured with a proportional component42, an integral component44, and/or a derivative component46. These components may in combination and/or independently be tuned by the control system12to minimize the error value40. The proportional component42may be dependent on the present error value, and may calculate an output value that is proportional to the current error value. The integral component44may be dependent on the accumulation of past or historical errors, and may calculate an output value that is proportional to both the magnitude of the error and the duration of the error. The derivative component46may be a prediction of future error based on the current rate of change of the error over time. In certain embodiments, one or more of the output values calculated by the proportional, integral, and/or derivative components42,44, and/or46may be summed (e.g., weighed sum) with a second adder48, and may be utilized to produce control signals17that adjust various operating parameters of the process system10.

In particular, in certain embodiments, one or more of the components of the control system12(e.g., the proportional component42, the integral component44, and/or the derivative component46) may utilize the preload value23to initialize the control system12at a predetermined level. For example, in the illustrated embodiment, when the control system12receives an initial feedback signal from the process system10(such as when the process system10transitions from the sleep mode to the wake mode), the integral component44may retrieve and load the preload value23from the memory22of the control system12. Further, the integral component44may utilize the preload value23to start at a predetermined level. For example, the integral component44may initialize at a predetermined initial feedback value based on the preload value23and the input devices feedback34, as opposed to initializing at an actual feedback value based only on the input devices feedback34. The integral component44may calculate an output value that is proportional to both the magnitude of the error and the duration of the error based at least in part on the preload value23and the input devices feedback34. In this manner, the control system12may utilize the preload value23to manipulate the input devices feedback34to cause the process system10to provide an output that is closer to the desired setpoint value30. It should be noted that utilizing the preload value23in addition, or in some cases, as a substitute for the input devices feedback34, may help increase the response speed of the process system10in achieving the desired setpoint more quickly, as further described below.

In certain embodiments, the preload value23is utilized within the control system12to enhance the response speed of the process system10as the process system10transitions from a sleep mode to a wake mode, such as when the process system10detects a demand request. Indeed, the response speed of the process system10may be described, for example, as the speed with which the process system10exits a sleep mode to meet a detected demand or a achieve a desired setpoint value30for an output of the process system10. As noted above, utilizing the preload value23within the control system12may help to initialize the control system12at a predetermined feedback level or threshold, thereby helping the process system10achieve the desired setpoint value or meet the detected demand more quickly. It certain embodiments, initializing the control system12with the preload value23may help to reduce a number of iterations of the feedback loop28, thereby tuning the control signals17more efficiently and effectively.

For example, when transitioning from a sleep mode to an active mode, the control system12may receive a command to activate the process system10to achieve a desired output. As such, in one embodiment, the control system12may increase the output of the process system10, receive input device's feedback34regarding the output of the process system10, and adjust the output devices16of the process system10based on a difference between the input devices feedback34and the desired setpoint value30. In some situations, several iterations of the feedback loop28of receiving input devices feedback34and fine tuning the control signals17may be used to drive the process system10to the desired setpoint value30. In certain embodiments, utilizing the preload value23within one or more components of the control system12(e.g., integral component44) may start or initialize the control system12at a specific predetermined feedback level, such that the process system10achieves the desired setpoint value30more quickly, without overshooting the desired output values of the process system10.

For example, when the water distribution system enters a sleep mode, the control system12communicatively coupled to the water distribution system may continue to operate, but may also enter a sleep or reduced activity mode. The water distribution system, upon detecting a demand for the water output via sensors (e.g., a pressure sensor) and/or operator input, may transition from the sleep mode to the active mode and provide an initial feedback signal or wake activation signal to the control system12. Accordingly, the control system12may receive the initial feedback signal or wake activation signal and may also transition into the wake mode. In some of these situations, the error value40(e.g., the difference38between the setpoint value30and the input devices feedback34) may be large as the process system10resumes operations to meet the demand. The control system12may also have a slow response speed in providing control signals that meet the sudden output demand of the process system10, thereby resulting in a sluggish response and/or overshooting the desired output values of the process system10.

Accordingly, as noted above, utilizing the preload value23within the control system12may enhance the response speed of the process system10as it transitions from the sleep mode to meet a demand or a desired output. Specifically, in certain embodiments, the control system12may manipulate the input devices feedback34(e.g. initial feedback signal) at least in part on the preload value23, such that the control system12starts at a predetermined level immediately upon detecting the sleep-wake transition of the process system10. In this manner, for example, the control system12may bypass one or more iterations of the feedback signals15and/or control signals17to enhance the response speed of process system10in meeting the detected demand. In certain embodiments, the preload value23may be preloaded into the control system12through operator input and/or may be accessed from the memory22. In certain embodiments, after preloading the initial preload value23into the control system12, the preload value23may be determined and/or tuned through one or more iterations of the feedback loop28. For example, the preload value23may be determined via the one or more iterations of the feedback loop28after all gains in the control system12are determined.

The preload value23may be any value, percentage, range, or variable that is used by the process system10to describe a standard configuration or parameter of the process system10. In certain embodiments, the preload value23may be any value that may be utilized by the control system12to represent or substitute for actual feedback sensed by the process system10. Further, in certain embodiments, the preload value23may be a representation of an average of the amount of demand typically requested by the process system10. It should be noted the preload value23may be customized for different types of process systems10. For example, the preload value23may be different values depending on the type of process system10it is utilized within or depending on the type of feedback it is utilized to represent. For example, for a water distribution system, the preload value23may be a numerical value that translates to and/or is representative of the desired water output. In some situations, the preload value23may be a quantity of the water output, a flow rate of the water output, a temperature of the water output, a pressure of the water output, or any other operating parameter of the process system10that may be sensed and provided as a feedback signal15to the control system12. As a further example, for the water distribution system, the preload value23may be a percentage that translates to and/or is representative of the desired water output relative to the maximum water output capacity of the process system10. In some situations, the total capacity of the water distribution system may be any percentage between 0% to 100% or speed of motor (for water to flow) in unit Hertz or RPM. For example, the preload value23may be 70%, which is representative of a water output approximately equivalent to 70% of the total water output capacity. As a further example, for the water distribution system, the preload value23may be a numerical value that is representative of an average demand for the water output that is typically requested by the water distribution system.

FIG. 3illustrates exemplary logic for a method52for enhancing the wake activation response speed of the process system10ofFIG. 1, in accordance with embodiments of the present disclosure. In particular, the method50may be implemented by the processor18of the control system12, as discussed above with regard toFIGS. 1 and 2.

In certain embodiments, the method50includes the control system12receiving a wake activation signal from the process system10, indicating a transition of the process system10from the sleep mode to a wake mode (block52). In certain embodiments, the wake activation signal may be a feedback signal15that activates the feedback control loop28and provide an indication of the current operating parameters of the process system10(including a demand for the output of the process system10). As noted above, the process system10may often transition between a sleep mode and an active mode, depending on the demand for the output provided by the process system10. For example, in a water distribution system, the wake activation signal provided to the control system12may be indicative of a demand for the water. Indeed, the wake activation signal may be related to a current operating parameter of a pressure sensor, or any other type of input device14that detects the output demand that causes the process system10to transition to wake mode. If a wake activation signal is not detected from the process system10, the control system12continues to monitor the process system10until a wake activation signal is received indicating a change in status for the process system10.

In certain embodiments, if the wake activation signal (e.g., initial feedback signal) is received by the control system12, the control system12may retrieve the preload value23(block54) from the memory22. In certain embodiments, the preload value23may be a predetermined value that is configured for enhancing the response speed of the process system10as the process system10transitions from the sleep mode to meet a detected demand or achieve the desired setpoint value30. For example, for a water distribution system, the preload value23may be any value that may enhance the response speed of the process system10as it exits the sleep mode to meet a detected demand for the output of the water distribution system. For example, the preload value23may be a numerical value that translates and/or is representative of the desired water output of the water distribution system. In other embodiments, the preload value23may be any value that is a substitute for a sensed feedback of a parameter of the process system10. Indeed, the preload value23may be any value that the control system12may utilize to enhance the response speed of the process system10in minimizing or reducing the error value40(e.g., difference between the input devices feedback34and the desired setpoint value30). For example, the preload value23may be representative of a quantity, a flow rate, a pressure, a temperature, a percentage of the total water output, or any other value representative of the desired output of the water distribution system or representative of sensed feedback from the water distribution system. In certain embodiments, the preload value23may be received via user input and stored within the memory22, and may be customized for different types of process systems10. Further, in certain embodiments, one or more preload values23may be stored and accessed, and the control system12may select the preload value23based on the current operating conditions of the process system10, based on the wake-up signal received, based on the component of the control system12utilizing the preload value23, and/or based on characteristics of the demand of the output.

In certain embodiments, the retrieved preload value23is loaded into one or more components of the control system12(e.g., the integral component44) and utilized within the feedback control loop28(block56). For example, as noted above, the control system12may utilize the received input devices feedback34in combination with the setpoint value30. Specifically, the setpoint value30may be combined with the received input devices feedback34, and the resulting difference38is utilized by the control system12to represent the error value40. The control system12may minimize the error value40to cause the process system10to provide an output that is closer to the desired setpoint value30or the detected demand. It should be noted that in certain embodiments, the preload value23may be a predetermined value that is utilized by the control system12to bypass one or more iterations of the feedback control loop28. Accordingly, the control system12may be configured to minimize the error value40with enhanced efficiency and accuracy when utilizing the preload value23. Based at least in part on the preload value23, one or more components of the control system12(e.g., the proportional component42, the integral component44, and/or the derivative component46) calculate one or more control signals17that are tuned to control the process system10closer to the desired setpoint value30, such that the output demand of the process system10is met. Accordingly, the control signals17are sent to the output devices16of the process system10(block58). In this manner, the control system12may utilize the preload value30to enhance a response speed of the process system10during the sleep-wake transition period of the process system10. Further, it should be noted that after the control system12utilizes the preload value30, the control system12may receive one or more actual feedback signals from the process system10(block59). For example, the controls system12may receive real feedback from the input devices14and the input devices feedback34may be the actual current operating conditions of the process system10. Further, the control system12may regulate and monitor the process system10based on the actual feedback signals from the process system10.

It should be noted that in certain embodiments, it may be particularly beneficial for the control system12to utilize the preload value23within the feedback control loop28when it is desirable to reach the detected demand quickly or in the shortest time frame possible. In other words, the control system12may utilize the preload value23in order to quickly minimize the error value40to cause the process system10to quickly provide an output that is closer to the desired setpoint value30. For example, in situations where the feedback34is lagging (e.g., between approximately 1 and 5 seconds, 5 and 10 seconds, or more than 10 seconds) and/or in situations where process system12needs to reach the setpoint value30within a certain amount of time (e.g., between approximately 0 and 5 seconds, 5 and 10 seconds, etc.), the control system12may utilize the preload value23to quickly bring the process system12to meet the detected demand. In situations or embodiments where the process system12is allowed a longer time to reach the desired setpoint value30(e.g., approximately 15 seconds or more) or does not need to reach the setpoint value30immediately, the control system12may or may not utilize the preload value23. Indeed, in such situations, the process system12may have sufficient time to reach the desired setpoint value30or meet the desired demand without a great risk of overshooting the desired setpoint value30, as further explained with respect toFIG. 4.

FIG. 4is a graphical representation60of an exemplary output62of the control system12ofFIG. 1utilizing the preload value23, illustrated in comparison to an exemplary output64of a typical control system that does not utilize the preload value23, in accordance with embodiments of the present disclosure. In the illustrated embodiment, the exemplary outputs62,64are outputs61from a control system illustrated as a function of time63. Specifically, the output62from the control system12utilizes the preload value23to illustrate that the process system10may have a quicker response speed after detecting a process system wake event66. The process system wake event66may be a detected demand that causes the process system10to transition from a sleep mode to a wake mode. In response to the demand, the control system12may also transition to a wake mode to provide control signals17to the process system10to achieve the desired setpoint and/or to meet a demand of the process system10, thereby minimizing or reducing the error value40of the control system12.

With the forgoing in mind, the output62of the control system12that utilizes the preload value23may start at a predetermined initial output68. Indeed, as noted above, the preload value23may be utilized by the control system12to initialize the control system12and the initialize the control signals17at the predetermined initial output68. In certain embodiments, the preload value23may be utilized by the control system12to manipulate the initial feedback signals to cause the process system10to provide an output that may be closer to the desired output and/or meet the detected demand. In certain embodiments, such manipulation of the input devices feedback34may bypass one or more iterations of the feedback loop28to bring the output of the process system10closer to the desired output or demand. In certain embodiments, the control system12is pre-initialized at the predetermined initial output68, such that an output of the process system10is closer to a desired process system output72even when the initial input devices feedback34is further away from the desired process system output72. Further, after the pre-initialization, in certain embodiments, the control system12may receive real feedback from the process system10and further adjust the control signals17to tune the process system10such that it is closer to the demand and/or desired setpoint value30.

In contrast, the output64of a typical control system that does not utilize the preload value23does not start at the predetermined level68. For example, in the illustrated example, the control system12may be active while the process system10is inactive or asleep. Accordingly, the output64of the active control system12may be at the level70prior to the process system wake66. Further, when the process system10transitions from the sleep mode to the wake mode at the process system wake66, the output64of the typical control system may wake at a level71based on the initial feedback from the process system10. Further, due to a difference between the desired process system output72and the level71(e.g., error value40), the output of the typical control system may overshoot the desired process system output72as it attempts to adjust for the demand. Indeed, the typical control system may have to tune the control signals provided to the process system10in multiple iterations of the feedback control loop28in order to drive the output64toward the desired process system output72. Accordingly, as noted above, utilizing the preload value23within the control system12may enhance the response speed (e.g., wake activation response speed) and the efficiency of the process system10as the process system transitions from the sleep mode to the wake mode to meet a detected demand.