THE AUTONOMOUS SYSTEMS LABORATORY

Ricardo Sanz

Heterogeneous Software Integration for IPC

The HINT Project
ASLab v 0.0 Draft | 1998-08-13

Contents
1 2 Introduction: Intelligent Process Control Heterogeneous Problems and Heterogeneous Solutions 2.1 2.2 2.3 3 4 5 Complex Process Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heterogeneous Software Solutions . . . . . . . . . . . . . . . . . . . . . . . . . The Need for Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 3 5 6 7 8 9 9

Life cycles for Intelligent Process Control HINT Objectives HINT Components and Technology 5.1 5.2 5.3 HINT Integration Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . .

HINT Integration Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HINT Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 12 14 15 16

6 7 8 9

HINT Demonstration HINT Now and Tomorrow: DIXIT Conclusions Acknowledgments

10 References

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Introduction: Intelligent Process Control

In complex continuous process plants there has been a traditional gap between control requirements and control capabilities of control systems. Conventional controllers were unable to cope with all the problems that lead to bad operation of the plant. Dependability and safety were the main criteria that led to the use of humans to perform control tasks in these systems. The introduction of articial intelligence [Boullart 92] was seen as a major step towards plant autonomy, because of the potential capability of emulating high level human behavior. Expert systems were the tools mostly used to put intelligence in process controllers. Intelligent process control is the subarea of automatic control that deals with the use of advanced computer technology to attack control problems in a process plant. This is traditionally related with complex process control and articial intelligence (AI), but -for sure- a control system is more intelligent if it uses the best solution to a problem and not only AI based solutions. Our group has been involved in the development of control applications for complex processes for several years: cement, pharmaceutical, plastics, petroleum, chemical, etc. The architectural complexity of the systems varied from simple expert systems running on small computers controlling batch fermentation processes (SECOFE) to heterogeneous, multilayered, distributed applications controlling cement kilns (CONEX [Sanz 91]). The activities in CONEX [Sanz 90] and the other systems gave rise to our participation in the HINT project (Heterogeneous INTegration architecture for intelligent control systems). HINT was an ESPRIT project (#6447), partially funded by the Commission of the European Communities, which has produced a coherent framework for integrating different techniques, in particular AI ones, in order to overcome the obstacles mentioned in the above paragraphs and to provide solutions to process control problems which require the kind of intelligent supervision that is presently carried out by human operators. The HINT Project tried to cope with a recurring problem in complex process control: the need of integration of heterogeneous software components in a complex process control system. These components are new or legacy components performing activities in restricted areas: covering partial domains, performing simple functions and using single technologies. The results from the HINT Project were: An integration methodology An integration architecture A set of problem solving components In this paper we present an overview of the HINT project, explaining its objectives and analysing the integration technology developed. First we will try to characterise the application domain of HINT. Next a life cycle for intelligent controllers is presented. HINT objectives and technology are analysed afterwards. Finally a brief assessment and a view of the immediate future is presented with some conclusions.

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Figure 1: sample intelligent process control application architecture (From [MITA 1994]). It shows the need
of integrating heterogeneous control processors. Fuzzy, neural and expert in this case, with the added difculty of learning.

Heterogeneous Problems and Heterogeneous Solutions

When trying to assess HINT for this paper -in relation with COSY- we found the following statement in the COSY web pages: ?In particular, the COSY Programme will have the goal to study tools which are capable of analysing control systems with the increased complexity and hybrid nature resulting from compatible, consistent use of combined heuristic, quantitative and qualitative information, together with expert knowledge, in a supervised control system architecture? As we will see, HINT objectives are strongly related with COSY objectives.

2.1

Complex Process Problems

In big, complex plants, there exist lots of operation and control problems. The origins of the problems are diverse, but the nal issue is that conventional control technologies are not capable to solve them. The problems can span from the lower control levels (sensors and actuators) to the higher ones (advanced controllers, reliability of models, human misoperations, etc.). We are talking about problems, but in some cases, there are other type of tasks that are not problems, but should be solved in order to get a better behaviour of the plant. The complexity of the control of this plants is reected in the structure of a complex process control system. Figure 2 shows a pyramidal view of complex process control. The abstraction level increases when going upwards, at the same time that speed and -more important- responsiveness decreases.

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Management

Management Information System

Monitorization and Control Perception Action

Optimization

Strategical Layer

hours-days

Plan Execution

Tactical Layer

mins-hours

Operational Layer

secs-mins

Advanced Control

1 sec

Complex Loops Conventional Control Single Loops

100 msec

10 msec

Sensors & Actuators

msec Action

Plant

Perception

Continuous Process Plant

Figure 2: Control layers in complex process control systems. Intelligent components are used in all the layers
of the control pyramid. HINT problem solving components are targeted at reactive an tactical layers (Adapted from [HINT 94]).

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User Interface

Reactiveness

Conventional process control spans from layer one to layer four (sensors to advanced control). Intelligent control is usually viewed as part of the upper layers, but, depending on the technology, it can be used also in lower layers. By example, we have been using fuzzy inference technology in the sensor layer to perform sensor validation. This is possible because speed of our fuzzy inference engines and predictability of the fuzzy validator makes possible its use in fast real-time layers. The complex process control is so complex that, in most cases, human supervision must be done for all layers. 2.2 Heterogeneous Software Solutions

If you browse one volume of proceedings from an IEEE Intelligent Control Symposium or IFACs AIRTC, you will see lots of demonstrations of software solutions to complex plant problems or tasks; but what you will not see is a clear map from problems to solutions. It seems possible to use all the techniques in all the problems. For a hammer everything seems like a nail. For a neural networker every problem is obviously better solved using a neural network. In fact it is true that you can use whatever technique you want. At the end all you have is the Pentium or SPARC instruction set to do things1 . The hammer-nail problem is so extended that we have found expert systems written in FORTRAN and conventional procedures implemented by means of rules and articial state variables using an expert system shell. The software toolbox of the intelligent control systems engineer is big; it contains lots of software technologies sometimes complementary and sometimes diametrically opposed one to other. There have been efforts to characterise pairs problem-solution in restricted ar 1995]. But in fact the nal eas (See by example [Leitch 93]) and even more globally [Alarcon tool chosen depends on the persons that will construct the solution more that it depends 93]. on the problem to be solved. This effort has been done even in HINT [Alarcon Sample Tasks Process interfaces Situation assessment Direct control Simulation Diagnosis Data validation Data visualization Data estimation . . . and many more. Sample Software Solutions Conventional programming Expert systems Neural networks Fuzzy Logic Model based reasoning Genetic algorithms GUIs Databases . . . ad innitum.

What is the solution ?. Perhaps what we need is a better assessment of the technologies in relation with problems of a domain. We call it a domain-task-technology (DTT) theory.
1 From our point of view what is critical is not technology capability but personal capability. At the end, when you are running an intelligent control project, you have persons working towards the solution. The technical knowledge of these persons is a good point to start searching for a solution. Sometimes it is best to use a not so suitable technology because you have personnel knowledgeable in technologies away from the most suitable. The problem in this case is for your contractor, not for you; because he will reach a not so suitable solution but you will maximise your prot.

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Perhaps the bets way is to leave the developers the technological decision. Perhaps they dont select the best technology, but the will select the technology the are more condent with. In any case, when confronting heterogeneous problems, we will end with a set of heterogeneous technologies to solve them. If we use a DTT theory because the set of tasks will conform the set of technologies. If we dont use such a theory, the set of persons in the project team will conform this set of software technologies based on technologies in which they are knowledgeable. As an example, the following table shows part of a DTT theory developed as part of the HINT Methodology. We will se details of this table later, when referring to HINT Technology. 2.3 The Need for Integration

If we have a set of technologies, there appears a problem when building the intelligent controller. The application architecture for each technology, its data sources and products, the data formats and abstraction levels, will produce a software engineer nightmare if trying to design a single, compact application. If using a shell to build this application we need something like a Swiss-army-knife shell. Gensym is trying to do this with G2. The other alternative is to employ several tools to build application components and integrate them in a single application. The keyword is integration. This word is a typical candidate for the lots-of-uses/no-meaning syndrome. When we use this term we meanmaking several things work together. And, when referring to software applications it means making several portions of code work together. Software integration is what a linker does with program parts. But our problem is more complex, because the parts are built in different ways and the input/output mechanisms are not as simple as parameter passing in a programming language. When trying to identify the integration needs and issues we will talk about: Core Technologies Integration Methodology Integration Architectures Core technologies specify the way components are built. Each technology opens a path to specic code and data structures. By example, talking about expert systems -a core technology- it is assumed that there will be a explicit representation of application dependent knowledge -the knowledge base- that will be used by an application independent code -the inference engine. Integration methodology specify how to perform the conceptual integration of the components. Integration architecture is software design -or even implementation- to provide mechanism to translate the conceptual integration specied by the methodology into real, working code.

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In HINT core technologies are technologies suitable for use in intelligent process control applications. Some components based on these technologies were developed. Some as reusable packages (fuzzy, neural, user interface) some as demonstrator specic code (expert, simulation, data capture). The integration methodology is the HINT Methodology. The integration architecture built to support the methodology was a blackboard based monohost architecture.

Life cycles for Intelligent Process Control

From the inner point of view, intelligent control systems design must begin with a careful operator task analysis and correct balance of responsibility. At the end humans are responsible of the correct operation of the whole system, so they must be condent with the automated activities of the control system. Success of advanced technologies in process control should not be measured by the economy gains or the reliability enhancements but by their operation time. The time that operators let them do their work. Finding a right way to build intelligent process control systems is a no hope task because of heterogeneity in process problems leads to a high degree of variety in application structure. Some of the reasons for the complexity of the search of a life cycle are: Use of articial intelligence technologies, which are inherently unpredictable and unplanicable2 . Non determinist computational methods. Knowledge based processing. Knowledge extraction problems. Knowledge representation problems. Application structure dynamics. Exploratory programming. High level of novelty Strong coupling between development phases: inherent feedback Postponed specications and designs Complex non-hierarchical development teams All these things lead to spiralled or prototype based development life cycles. But there exist another problem and is the problem of technology heterogeneity and the need of integration. This problem discovers a need for analysis of control problems and technology selection that must be done before any other work can start, because technologies selected will guide the design of the integrated application. This is where a DTT theory is involved.
2 Despite the efforts put on formalising life cycles for knowledge based systems like KADS [Schreiber 93] and similars.

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Figure 3: A view of the intelligent process control life cycle. In Figure 3 a way from a problem to a solution is depicted. We start at the left node, with a problem in a domain. And want to reach the lower node; a solution in that domain. The hammer-nail way is straightforward; directly from problem to solution without bothering about what is the best way to do that. The monotechnology, non integrated application is the easiest solution. We promote the other way round. We need a brief -or not so brief- stay in the two other nodes: task and component. In task we analyse and decompose the problems in conceptually elemental tasks. In Component we select the technology or technologies that offer better solutions for this tasks. The objective of HINT is to support this approach by means of providing mechanisms -conceptual and software- to perform the integration of heterogeneous components

HINT Objectives

The objective of HINT was provide technology for the three top layers of the control pyramid. These technology should provide support for integration of heterogeneous components. This was achieved by means of blackboard structuring around task oriented objects: The Basic Control Processes (or BCPs for short). The proposed pyramidal structure means: 1. The information available in each layer, as well as the control procedures present in it, become progressively more complex as we ascend. 2. The BCPs represent control procedures instantiated according to the objectives of each layer. These procedures are, as well, progressively more complex. 3. The development procedure operates under the exhaustive elaboration of the lower level layers and its installation and previous tests before taking into account the higher layers.

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4. Each layer is conceptually independent of higher layers, and in their absence a minimum control functionality is assured by default. 5. The information ow (BCPs input) is from lower layers to higher layers. Higher layers are responsible for gathering information at the right moment. The responsibility of the lower layers is to assure the availability of that information. 6. The ow of activities (BCPs output) is moderated by the deposition of information (tuning control loop parameters, for example) in accessible positions of the same or lower layers. The HINT project nished by the end of 1994 with partial success. This success was only partial because: The reusability of the code developed was not high. It is difcult to build a new application using HINT software. The strategic layer was not demonstrated. Distributed applications were not possible under HINT.

HINT Components and Technology

The main HINT components are: the HINT Integration Methodology, the HINT Integration Architecture and the HINT Components

5.1

HINT Integration Methodology

The HINT integration methodology: Denes when specic control problems are suitable to be solved by the cooperation of the different techniques. Species the different phases to follow when integrating different AI based technologies, namely the denition, analysis, knowledge acquisition, conceptualization and design phase. Denes the vehicles means by which this integration can be carried out: The BCPs. It is important to notice that the BCP structure is able to represent and support both automatic tasks already being performed in present control systems and those taking place in more intelligent layers. BCPs can be classied as one of the following four types according to their intrinsic features and objectives: Preventive : aiming to avoid possible problems before they appear by manipulating the corresponding variables or suggesting recommendations.

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Corrective : aiming to resolve undesirable situations once a problem is detected by performing or recommending appropriate actions. Optimization : aiming to carry out enhancements which improve the process. Modal : causes a change in the processes functioning, i.e., in the way that the operation team or the higher level staff carry out the process, usually in response to orders from higher levels. At present, these four types constitute all the possibilities from our point of view. They cover all the functionalities that might be needed to govern a process. Consider: at any moment, the process will be in a certain state and we might set three possible classications of the state, good, normal and bad. In the next moment the same classications are applicable, and we might postulate that the state transitions between these two instants are performed by a BCP. The transition from a normal state to a good one will be realized via an optimization BCP. A bad state passes to a normal one via a corrective BCP, and in order to avoid a change from a normal state to a bad one, a preventive BCP will be red. No other transitions are to be feasible within one layer. These are then the functions of the optimizing, corrective and preventive kinds of BCP. When an order or an action is performed in an upper layer, however, a BCP might be created in a lower layer as a result in order to do the bidding. The latter is the modal kind of BCP.

5.2

HINT Integration Architecture

The architecture for heterogeneous integration developed in HINT is based on the blackboard concept [Engelmore 88]. The HINT blackboard is structured in three layers (operational, tactical and strategical) according with the three conceptual layers proposed by the methodology. The contents of the blackboard are described using an specically developed language called the HINT blackboard Generation Language (GL) which describes the objects contained in each layer, its behaviour an the relations between objects in different layers. The GL compiler compiles the GL le into C code that implements blackboard data and blackboard manager procedures. The main object contained in the blackboard are HINT BCPs. They are constructed using the HINT generation language and based on the methodological design done for integration of heterogeneous knowledge sources based on the components. The knowledge sources access blackboard data using an interface library. The blackboard supports dynamic creation of objects, but the methodology recommends not to use it because of predictability penalties. The structure of a BCP object is shown in Figure 4. It is composed of: Start: the start point determines the activation of the BCP. It can be red automatically or by a trigger condition (e.g. a changing of a variable) or by an order from a higher level. Control phase, including:

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Presentation Stress
Control Phase
Detection Diagnosis Suggestions & Actions Actions Monitoring

Follow - Up
Predictive Reasoning Hypothesis Reevaluation and End Condition

Start
M11 Message M12 Message

End

Figure 4: Basic Control Process structure (From [HINT 1994]). 1. Detection: this may coincide with the start point, and usually depends on a condition involving several variables. During the BCPs lifetime, this step can be initiated several times. 2. Diagnosis: a diagnosis of the problem is provided. 3. Suggestions and Actions: according to detection and any diagnosis (if it exists), an action is performed or a recommendation is generated (if the loop is not closed). Presentation Stress: this determines the current priority, seriousness and state of stress of the BCP, affecting its presentation on the user interface. Follow-up phase, composed by: 1. Monitoring: the actions realized are detected and monitored, and the progress of the BCP and the evolution of the process are evaluated. 2. Prediction of the evolution of the BCP in order to determine whether to terminate the BCP or to continue. 3. Hypothesis re-evaluation and End conditions: the hypothesis (formed at the diagnosis stage) is reviewed and the decision is taken whether or not to return to the control phase (detection, diagnosis or action) or to go to the end step. End: this terminates the BCP. It initiates terminal processing. 5.3 HINT Components

Five components were planned as demonstration. The technologies for these components were:

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M33 Reevaluation

M2 Suggestion

M32 Predictions

M31 Actions Monitored

A1 Action

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 Neural networks Fuzzy logic Expert systems Model based reasoning Graphical user interfaces All they were shown in the demonstrator performing some tasks: assessment, validation, prediction, diagnosis. Some of the components that make up the HINT demonstrator can be customized in order to develop a new application. The HINT customization toolkit -or HINT Toolkitprovides the system developer with an integrated environment in which the customization and the test of the HINT system can be carried out. It allows the customization of the individual modules of the HINT application but also provides common features to coordinate the development and to test the applications. By means of this HINT Toolkit a system developer can customize a HINT application straightforwardly. The system developer is guided by means of a system developers manual -including the integration methodologywhich describes the complete development process - from knowledge acquisition to the actual implementation by means of the HINT Toolkit. The reusability of the demonstrator components were quite variable. The operator assessment expert system and neural netrok predictor were built for demonstration exclusively, but the fuzzy module provided a tool for building general fuzzy processors. The specic component part for the demonstrator was a knowledge base le. The rest (knowledge base editor and fuzzy knowledge source engine) were totally reusable. Usability -not reusability- of the model based reasoner was low even in HINT. The user interface builder was a very reusable and effective tool for building user interfaces based on a HINT blackboard.

HINT Demonstration

It is very important to note that, as part of the HINT project, a demonstrator has been implemented and installed in a petrochemical plant owned by Repsol S.A (one of the major Spanish rms and a member of the HINT consortium) in Cartagena, Spain, in order to be sure of the suitability of the approach. This demonstrator is currently being used by the control team of the plant and it is already showing very promising results. Several AI based modules have been developed in this demonstrator as an example of the various techniques that can be used in a HINT-like application, where the whole development -architecture, methodology and components- is oriented towards integrated man-machine systems. The HINT methodology provides a good way to achieve proper balancing between man and machine: the maquette approach to development. It is a type of rapid prototyping, but what provides the prototype is mostly look and feel and some little functionality. The maquette is developed in parallel with the real nal system -with reduced effort providing early feedback to get a better integration with plant systems and operators.

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Figure 5: A component customization tool: the Fuzzy Logic Shell. This tool is used to edit fuzzy knowledge
bases used by the run time fuzzy knowledge source.

From FL

From PI

From ES

Figure 6: Sample screen from Repsol Cartagena demonstrator. It shows and advanced energy view of the
ltering process section. It includes data from several knowledge sources.

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A big effort was put in the integration of human operators in the control system this was the main objective of the demonstrator. The components used were: A decision support system was the main component of the demonstration application (based on expert system technology). An advanced user interface based on abstract views of the plant were developed. A raw data validation and estimation system was done using fuzzy logic technology. A neural network based predictor was used to reason about future behaviour of the plant. A model based reasoner performed limited diagnosis of some subsystems.

HINT Now and Tomorrow: DIXIT

The architecture was a fairly simple monohost blackboard. In it a centralized and active data structure (the blackboard) is the only means of communication among problem solving modules. It is also the vehicle for cooperative problem solving and it is responsible for data coherence within the whole system. The interaction between knowledge sources and the blackboard is done using shared memory. It provides maximum speed but limits distributability. From a rst point of view we can say that HINT technology was -at least- immature, and that the HINT Product was unclear and barely useful. If we try to build -today- an application using HINT software we need a lot of information that is not really available. The HINT Developers Manual says quite a few about the real structure and use of the software. As a basic objective of DIXIT, reusability must be reached, and it must start from HINT technology reuse. So the rst work is the analysis of HINT products in order to get a reusability perspective of them. Another drawback of HINT is that id did not demonstrate the use of a strategical layer. This layer is mainly comprised by its global objectives. These global and strategic objectives of a plant can be divided into the following categories: Continuity: the objectives dene criteria which assure the overall continuity of the production process, as well as best alternative options. Maintenance: this includes objectives which evaluate operations that generate wear with the aim of reducing it, and the detection of possible problems (in the process) as a consequence of maintenance operations. Production: these objectives govern the net quantity of product obtained, using numerical measures. Quality: this class denes and establishes both internal and external criteria for quality and sets goals related to contractual constraints and sales requirements. Efciency: these objectives relate to the analysis of production costs. Structural and staff costs are not considered.

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 Safety: these objectives touch on all safety criteria affecting the integrity of equipment and components, the industrial installation, the plant staff, and third parties.

The problem is how to represent these objectives, how to provide reasoners on them and how to integrate them in the multilayer structure of the advanced control system. These three points (reusability, distributability and strategy) are the main targets of the new ESPRIT project DIXIT.

Conclusions

The main results of the project can be summarised in a methodology, an architecture and some problem-solving software components. The components developed were based on articial intelligence technologies and were situated in the full spectrum of automation layers. The development of an integration methodology was the main point in HINT. This development was aimed at facilitating and guaranteeing the coherent interaction between multiple heterogeneous techniques in the task of solving industrial control problems. This integration methodology (i) Denes when specic control problems are suitable to be solved by the co-operation of the different techniques, (ii) species the different phases to follow when integrating different AI based technologies and (iii) denes the vehicles means by which this integration can be carried out. The main concepts that appear behind the HINT architecture are the blackboard as an architectural schema and the concept of multilevel blackboard. We must change this two concepts in order to give them a wider meaning, fundamentally due to the system transformation from a centralized backboard to a distributed system. In the HINT architecture the higher part of the work was performed sequentially: only the modules having enough information were able to access common blackboard data. The rest of the knowledge sources expect patiently their turn to modify or read the backboard information. The main concept: the HINT backboard, continues being valid, given it is the more exible mechanism for interchanging information between components that use different software technologies, such us neural networks, fuzzy logic, expert systems, model based reasoning, etc. In spite of the valid HINT blackboard schema, it is clear that for the distributed application development, it must be complemented with an agent oriented system. In a blackboard system, the knowledge bases must accomplish all their communications using the blackboard. In a mixed system, usually the most of the transactions ow through the backboard but other kind of communications are allowed. Now the knowledge bases are called agents and the direct communication between agents are supported by the system. The concept of a leveled control hierarchy continues been perfectly valid. This hierarchy reect a clear reality in manufacturing plants. The control is made in different levels of increasing speed and decreasing intelligence as we go up to the higher levels.

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Acknowledgments

We would like to acknowledge the funding from the Commission of the European Union through ESPRIT Project 6447 HINT.

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References

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Title Subtitle Author Date Reference URL

Heterogeneous Software Integration for IPC

The HINT Project Ricardo Sanz 1998-08-13 v 0.0 Draft

(C)

THE AUTONOMOUS SYSTEMS LABORATORY