DESC:FIELD
The present disclosure relates to the field of automation systems for terminals. Particularly the present disclosure relates to a terminal automation system for automating and coordinating different operations of terminals.
BACKGROUND
Conventionally, terminal automation systems are used to control human machine interfaces (HMI) and enable communication between various field devices like distributed control systems, PLCs, batch controllers, flow computers, card readers and the like. Typically, the terminal automation systems have three levels to communicate with Enterprise resource planning (ERP) systems and, to manage, monitor and control complete handling process for products right from receiving to storage to distribution. Traditionally, the terminal automation systems are monolithic, which means that the systems function with the help of fixed components that form a single block. Due to this, if a certain component/functionality fails, the entire system is unable to operate to provide desired outcomes. Moreover, if certain functionality needs to be modified which is not attainable using the existing components, a new component is required to be added. Along with the new component, corresponding hardware is required to be added to make the new component compatible with the existing components. This results in increased cost and risk of breaking existing component.
Therefore, to limit the aforementioned drawbacks, there is a need for a modular terminal automation system.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a terminal automation system.
Another object of the present disclosure is to provide a terminal automation system which is modular in nature.
Still another object of the present disclosure is to provide a terminal automation system that ensures very low impact area because of failure of a component.
Further, an object of the present disclosure is to provide a terminal automation system that is scalable.
Yet another object of the present disclosure is to provide a terminal automation system that lowers production costs.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a computer implemented terminal automation system cooperating with an ERP system for managing, monitoring, and controlling handling processes for products based on customer requirements. The system comprises a memory, a processor, a database, and an integrated core framework. The memory stores a set of predetermined rules and a set of predefined workflows corresponding to the customer requirements. The processor cooperates with the memory and processes the workflows to generate system processing commands based on the stored predetermined rules and the workflows. The database stores historical transactional data between the system and the ERP system. The integrated core framework cooperates with the processor to manage, monitor, and control the handling processes. The integrated core framework includes an ERP interface module, at least one device interface module, at least one operation module, a redundancy module, at least one MODBUS interface module, and an Electronic Display Unit (EDU) interface module.
The ERP interface module cooperates with the database and provides interface for data communication between the system and the ERP system, the ERP interface module further updates the historical transactional data based on the data communication. The at least one device interface module enables communication of the system with a plurality of field devices based on the system processing commands to enable the system to manage the handling processes. The at least one operation module cooperates with the processor and enables periodic operations of the system based on the system processing commands to enable the system to control the handling processes. The redundancy module cooperates with the processor and monitors the ERP system to determine a plurality of failure conditions of the ERP system based on the system processing commands. The at least one MODBUS interface module enables, based on the system processing commands, communication with a plurality of MODBUS based devices to enable the system to monitor the handling processes. The Electronic Display Unit (EDU) interface module enables, based on the system processing commands, communication with a plurality of EDU devices to enable monitoring of the handling processes.
Further, the system comprises at least one device interface component that provides communication between the at least one device interface module and the plurality of field devices, at least one MODBUS interface component that provides communication between the at least one MODBUS interface module and the plurality of MODBUS based devices, and at least one EDU interface component that provides communication between the EDU interface module and the plurality of EDU devices.
In one embodiment, the ERP system includes at least one ERP server and at least one ERP client. In another embodiment, the processor includes a modifier that cooperates with a plurality of customers and modifies the workflows based on customer requirements from the plurality of customers. The redundancy module continuously monitors the ERP system. Further, the plurality of field devices includes batch controllers and card readers, and the MODBUS based devices include density meters, density probes and GSM modems. In one embodiment, the periodic operations include reports generation, data backup, data restore, end of day log, and end of shift log.
The present disclosure also envisages a computer implemented terminal automation method for managing, monitoring, and controlling handling processes for products based on customer requirements. The method comprises the following:
• storing, in a memory, a set of predetermined rules and a set of predefined workflows corresponding to the customer requirements;
• processing, by a processor, the workflows to generate system processing commands based on the stored predetermined rules and the workflows;
• storing, in a database, historical transactional data between a terminal automation system and an ERP system; and
• managing, monitoring and controlling the handling processes by an integrated core framework, the core framework including steps of:
o providing, with an ERP interface module, interface for data communication between the system and the ERP system, and updating the historical transactional data based on the data communication;
o enabling by at least one device interface module, communication of the system with a plurality of field devices based on the system processing commands to enable the system to manage the handling processes;
o enabling by at least one operation module, periodic operations of the system based on the system processing commands to enable the system to control the handling processes;
o monitoring by a redundancy module, the ERP system to determine a plurality of failure conditions of the ERP system based on the system processing commands;
o enabling by at least one MODBUS interface module, based on the system processing commands, communication with a plurality of MODBUS based devices to enable the system to monitor the handling processes; and
o enabling, by an Electronic Display Unit (EDU) interface module, based on the system processing commands, communication with a plurality of EDU devices to enable monitoring of the handling processes.
Further, the method also comprises the steps of providing by at least one device interface component, communication between the at least one device interface module and the plurality of field devices; providing by at least one MODBUS interface component, communication between the at least one MODBUS interface module and the plurality of MODBUS based devices; and providing by at least one EDU interface component, communication between the EDU interface module and the plurality of EDU devices.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The terminal automation system and a method thereof, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic representation of an architecture of a conventional terminal automation system;
Figure 2 illustrates a schematic block representation of a terminal automation system in accordance with one embodiment of the present disclosure; and
Figure 3 illustrates a flow diagram of a terminal automation method in accordance with one embodiment of the present disclosure.

List and details of reference Numerals used in the description and drawing:
Reference Numeral Reference
100 Conventional terminal automation system
102 ERP system
102a At least one ERP server
102b At least one ERP client
104 System server
106 Client
108a, 108b, …., 108n Plurality of application servers and modules
110a, 110b,…., 110n, 112a, 112b, ….., 112n, 114a, 114b,….., 114n Plurality of field devices
200 Terminal automation system
204 Processor
206 Memory
208 Integrated core framework
210 ERP interface module
212 At least one operation module
214 At least one device interface module
216 Redundancy module
218 At least one MODBUS interface module
220 EDU interface module
222 At least one device interface component
224 A plurality of field devices
226 Database
228 MODBUS based devices
230 Electronic Display Unit (EDU) devices
232 At least one MODBUS interface component
234 At least one EDU interface component

DETAILED DESCRIPTION
Conventionally, the terminal automation systems are monolithic and have three levels. Figure 1, of the accompanying drawing illustrates a schematic representation of architecture of a conventional terminal automation system 100 which communicates with the ERP system 102. The conventional terminal automation system 100 consists of three levels (a first level, a second level and a third level) wherein the third level includes a system server 104 and clients 106 arrangement. The second level is a process automation system which includes plurality of application servers and modules 108a, 108b, …., 108n depending on the functionalities provided by the conventional terminal automation system 100. The first level includes field equipments having a plurality of field devices 110a, 110b,…., 110n, 112a, 112b, ….., 112n, and 114a, 114b,….., 114n and so on which are controlled and monitored by the systems in the second level.
The conventional terminal automation system 100 communicates with the ERP system 102 for order management & load scheduling. Consider an example, where the conventional terminal automation system 100 is used for automation of a central facility which distributes fuel to local fuel pumps. An owner of a fuel pump places request of petrol requirement with the ERP system 102. The request includes quantity of petrol required by the owner and also includes a vehicle number along with driver details who will be collecting the requested petrol from the facility in a vehicle having the provided vehicle number. This request along with other related information is collected by at least one ERP server 102a present in the ERP system 102 and conveyed to the system server 104 of the conventional terminal automation system 100 for further processing and action. The system server 104 analyzes the request and provides it to the relevant process automation system on level two. For example, the general information related to the truck may be provided to the application server 108a and quantity requirement information may be provided to a loading operation module 108b. Similar relevant information and commands are conveyed to the modules in the second level. Based on these details and commands the field equipments in level one are controlled and operated to provide quantity of fuel to the owner as per his request. The field devices include devices to control entry/exit into/out of the facility, vehicle tank gauging devices, flow measurement control devices, analyzers, batch controllers, card readers, and, pump and valve control devices etc. All these devices are controlled based on customer requirements.
If the customer or the facility owner requests any functionality modification, the modification request is sent to the system server 104 which cooperates with the client 106 to implement the modification. If this modification/implementation is not possible at the third level, at least one ERP client 102b handles the request and conveys the necessary modifications to the system server 104. The system server 104 provides commands to the second and first level to carry out the necessary changes. Once the requested petrol is provided to the pump owner, the information is conveyed to the at least one ERP server 102a by the system server 104, based on which the at least one ERP server 102a generates the invoice which is then provided to the pump owner by the conventional terminal automation system 100.
As the conventional terminal automation system 100 is monolithic in nature, it will not operate as desired even if a single module fails to operate. Moreover, if certain functionality needs to be modified which is not implementable using the existing modules and hardware, a new module and extra hardware is required to be added to make the new component compatible with the existing components which in turn increases the cost of the entire system. To limit these drawbacks, the system of the present disclosure is designed to be modular in nature. The terminal automation system of the present disclosure eliminates the third level of the conventional terminal automation system 100 by eliminating the system server 104 and the client 106 of the third level and creating a virtual third level using the application servers of the second level. The envisaged architecture for the terminal automation system of the present disclosure ensures that area impacted, because of failure of a certain module/component/functionality, is very low.
Figure 2 of the accompanying drawing illustrates a schematic representation of an architecture of a terminal automation system 200 in accordance with one embodiment of the present disclosure. The terminal automation system 200 includes two levels (a first level and a second level). The third level of the conventional terminal automation system 100 is implemented using the modules/components from the second level of the terminal automation system 200 of the present disclosure. In an embodiment, trending, historization, audit trail and events etc. can be recorded at clients using modules/components of the second level of the terminal automation system 200. The terminal automation system 200 cooperates with the ERP system 102 to manage, monitor and control complete handling process for products as per requirements of customers. An integrated core framework 208 is present in the second level of the terminal automation system 200. The integrated core framework 208 along with some of the first level modules, virtually create a third level for the for terminal automation system 200.
The integrated core framework 208 includes an ERP interface module 210 which provides interface for data communication between the terminal automation system 200 and the ERP system 102. The ERP interface module 210 uses a database 226 to store transactional data between the terminal automation system 200 and the ERP system 102 so that it can perform its functions/operations irrespective of statuses of other modules/components. At least one device interface module 214 is present in the integrated core framework 208 which enables communication with a plurality of field devices 224 through at least one device interface component 222. In one embodiment, a plurality of device interface components are present that control the plurality of field devices 224 including batch controllers and card readers. The at least one device interface module 214 also processes workflows that are configured outside the at least one device interface module 214. A processor 204 is present in the terminal automation system 200 in order to configure/modify workflows to suit customer requirements. For example, when a customer requests to modify a certain functionality provided by a terminal automation system, in the conventional terminal automation system 100, the request needs to be handled by the third level through time consuming component development cycle which normally takes months to take effect. However, in case of the terminal automation system 200 of the present disclosure, workflows can be locally added/modified by site/project engineer to add/modify certain functionality as per the request. The workflows are stored in a memory 206 along with a set of predetermined rules and processed by the processor 204 to generate system processing commands based on the stored predetermined rules and workflows. The added/modified workflows are processed with the help of processor 204 and the at least one device interface module 214 which operates irrespective of statuses of other modules/components. In an embodiment, the memory 206 may include any computer-readable medium including volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. In one embodiment, the set of predetermined rules include rules necessary for monitoring, managing, and controlling different handling processes for various products. In another embodiment, the processor 204 may be implemented as one or more microcontrollers, microprocessors, microcomputers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor 204 may be configured to fetch and execute computer-readable instructions or rules that may be stored in the memory 206.
The integrated core framework 208 also includes at least one operation module 212, a redundancy module 216, at least one MODBUS interface module 218 and an Electronic Display Unit (EDU) interface module 220. The at least one operation module 212 is mainly responsible for periodic operations of the system 200 such as reports generation, data backup/ restore, End of Day, End of Shift etc. In one embodiment, the redundancy module 216 is configurable and is not limited to terminal automation domain. Executable functions/modules of other systems can be configured using the redundancy module and it can be used for other systems. Several failure conditions for servers and/or devices are monitored by the redundancy module 216 before it decides to switchover to other standby servers and/or devices. The at least one MODBUS interface module 218 enables communication with specific MODBUS based devices 228 with the help of at least one MODBUS interface component 232. Read/ write operations can be configured external to the modules with the help of the at least one MODBUS interface module 218. In one embodiment the at least one operation module 212, the at least one device interface module 214, and the at least one MODBUS interface module 218 have multiple instances instead of single instance. In another embodiment, the MODBUS based devices 228 include a density meter, a density probe, a GSM modem and the like. The EDU interface module 220 is configurable and communicates with Electronic Display Unit devices 230 with the help of at least one EDU interface component 234. Write operations can be configured external to the EDU interface module 220. The EDU interface module 220 also controls announcing and displaying information related to the products/services provided with the help of the terminal automation system 200.
All the modules of the integrated core framework 208 perform their operations/functions irrespective of statuses of each other. This means that if a single functionality/module fails, the complete terminal automation system 200 is not affected. Also, only the module which is not functioning as desired can be worked upon or replaced without affecting the entire working. In one embodiment, the system 200 supports Object Linking & Embedding for process control (OPC) and TCP/IP communication protocols.
The terminal automation system 200 of the present disclosure eliminates the requirement of separate hardware for third level and ensures robustness of the system 200. It eliminates the bottleneck of GUI modifications at runtime, enables communication with card readers/batch controllers of different makes & provides dynamic workflow configuration. The terminal automation system 200 of the present disclosure implements natively integrated architecture which has a centralized view of terminal operations. In one embodiment, the system 200 of the present disclosure reduces foot print thereby reducing cost of hardware. As the third level is physically eliminated and virtually incorporated, it reduces the time delay and provides seamless interface between the system 200 and third party subsystem interfaces. The architecture of the terminal automation system 200 of the present disclosure is easily scalable and configurable, and can be easily upgraded. In an embodiment, the terminal automation system 200 provides configurable GUI.
In an embodiment, the terminal automation system 200 of the present disclosure ensures safe tank operation by providing a dual layer interlock check. In another embodiment, a server in the integrated core framework 208 is independent of processes of the field devices 224, thereby increasing availability of the terminal automation system 200 (as it will not be completely offline). Further, in another embodiment, the terminal automation system 200 of the present disclosure can be virtualized using cloud based technology. In one embodiment, the terminal automation system 200 of the present disclosure provides improves flexibility, efficiency, safety and accuracy.
Further, in an embodiment, the terminal automation system 200 provides single natively integrated platform with 100 msec scan rate execution for workflow & IO’s, accurate & faster management information, hot standby redundancy between the Terminal servers, intuitiveness & device diagnostics realized in Terminal Automation software, efficient operational controls, plant asset management, terminal workflow, sequence programming using IEC 61131-3 specifications, natively integrated SIL3 safety system eliminating the mapping of data using serial communication, easy software upgrade of Hardware/Software and virtualization platform support.The present disclosure also envisages a computer implemented terminal automation method for managing, monitoring, and controlling handling processes for products based on customer requirements. Figure 3 of the accompanying drawing illustrates a block diagram of a terminal automation method 300 in accordance with an embodiment of the present disclosure. The method 300 comprises the following:
• storing, in a memory, a set of predetermined rules and a set of predefined workflows corresponding to the customer requirements 302;
• processing, by a processor, the workflows to generate system processing commands based on the stored predetermined rules and the workflows 304;
• storing, in a database, historical transactional data between a terminal automation system and an ERP system 306; and
• managing, monitoring and controlling the handling processes by an integrated core framework 308, the core framework including steps of:
o providing, with an ERP interface module, interface for data communication between the system and the ERP system, and updating the historical transactional data based on the data communication;
o enabling by at least one device interface module, communication of the system with a plurality of field devices based on the system processing commands to enable the system to manage the handling processes;
o enabling by at least one operation module, periodic operations of the system based on the system processing commands to enable the system to control the handling processes;
o monitoring by a redundancy module, the ERP system to determine a plurality of failure conditions of the ERP system based on the system processing commands;
o enabling by at least one MODBUS interface module, based on the system processing commands, communication with a plurality of MODBUS based devices to enable the system to monitor the handling processes; and
o enabling, by an Electronic Display Unit (EDU) interface module, based on the system processing commands, communication with a plurality of EDU devices to enable monitoring of the handling processes.
Further, the method 300 also comprises the steps of providing by at least one device interface component, communication between the at least one device interface module and the plurality of field devices; providing by at least one MODBUS interface component, communication between the at least one MODBUS interface module and the plurality of MODBUS based devices; and providing by at least one EDU interface component, communication between the EDU interface module and the plurality of EDU devices.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of:
• a terminal automation system;
• a terminal automation system which is modular in nature;
• a terminal automation system that ensures very low impact area because of failure of a component;
• a terminal automation system that is scalable; and
• a terminal automation system that lowers production costs.
The disclosure is described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation

,CLAIMS:1. A computer implemented terminal automation system (200) cooperating with an ERP system (102) for managing, monitoring, and controlling handling processes for products based on customer requirements, said system (200) comprising:
2.
a memory (206) configured to store a set of predetermined rules and a set of predefined workflows corresponding to said customer requirements;
a processor (204) adapted to cooperate with said memory (206) and configured to process said workflows to generate system processing commands based on said stored predetermined rules and said workflows;
a database (226) configured to store historical transactional data between said system (200) and said ERP system (102); and
an integrated core framework (208) configured to cooperate with said processor (204) to manage, monitor, and control said handling processes.

3. The system as claimed in claim 1, said integrated core framework (208) comprises:
an ERP interface module (210) adapted to cooperate with said database (226) and configured to provide interface for data communication between said system (200) and said ERP system (102), said ERP interface module (210) further configured to update said historical transactional data based on said data communication;

at least one device interface module (214) configured to enable communication of said system (200) with a plurality of field devices (224) based on said system processing commands to enable said system (200) to manage said handling processes;

at least one operation module (212) adapted to cooperate with said processor (204) and configured to enable periodic operations of said system (200) based on said system processing commands to enable said system (200) to control said handling processes;
a redundancy module (216) adapted to cooperate with said processor (204) and configured to monitor said ERP system (102) to determine a plurality of failure conditions of said ERP system (102) based on said system processing commands;
at least one MODBUS interface module (218) configured to enable, based on said system processing commands, communication with a plurality of MODBUS based devices (228) to enable said system (200) to monitor said handling processes; and
an Electronic Display Unit (EDU) interface module (220) configured to enable, based on said system processing commands, communication with a plurality of EDU devices (230) to enable monitoring of said handling processes.

4. The system as claimed in claim 2, which comprises:
at least one device interface component (222) configured to provide communication between said at least one device interface module (214) and said plurality of field devices (224);

at least one MODBUS interface component (232) configured to provide communication between said at least one MODBUS interface module (218) and said plurality of MODBUS based devices (228); and
at least one EDU interface component (234) configured to provide communication between said EDU interface module (220) and said plurality of EDU devices (230).

5. The system as claimed in claim 1, wherein said ERP system (102) includes at least one ERP server (102a) and at least one ERP client (102b).

6. The system as claimed in claim 1, wherein said processor (204) includes a modifier adapted to cooperate with a plurality of customers and configured to modify said workflows based on customer requirements from said plurality of customers.

7. The system as claimed in claim 2, wherein said redundancy module (216) continuously monitors said ERP system (102).

8. The system as claimed in claim 2, wherein said plurality of field devices (224) includes batch controllers and card readers, and said MODBUS based devices (228) include density meters, density probes and GSM modems.

9. The system as claimed in claim 1, wherein said periodic operations include reports generation, data backup, data restore, end of day log, and end of shift log.

10. A computer implemented terminal automation method for managing, monitoring, and controlling handling processes for products based on customer requirements, said method comprising the following:

11.
storing, in a memory (206), a set of predetermined rules and a set of predefined workflows corresponding to said customer requirements;
processing, by a processor (204), said workflows to generate system processing commands based on said stored predetermined rules and said workflows;
storing, in a database (226), historical transactional data between a terminal automation system (200) and an ERP system (102); and
managing, monitoring and controlling said handling processes by an integrated core framework (208), said integrated core framework (208) including steps of:
providing, with an ERP interface module (210), interface for data communication between said system (200) and said ERP system (102), and updating said historical transactional data based on said data communication;
enabling by at least one device interface module (214), communication of said system (200) with a plurality of field devices (224) based on said system processing commands to enable said system (200) to manage said handling processes;
enabling by at least one operation module (212), periodic operations of said system (200) based on said system processing commands to enable said system (200) to control said handling processes;
monitoring by a redundancy module (216), said ERP system (102) to determine a plurality of failure conditions of said ERP system (102) based on said system processing commands;
enabling by at least one MODBUS interface module (218), based on said system processing commands, communication with a plurality of MODBUS based devices (228) to enable said system (200) to monitor said handling processes; and
enabling, by an Electronic Display Unit (EDU) interface module (220), based on said system processing commands, communication with a plurality of EDU devices (230) to enable monitoring of said handling processes.

12. The method as claimed in claim 9, which comprises the following:
providing by at least one device interface component (222), communication between said at least one device interface module (214) and said plurality of field devices (224);
providing by at least one MODBUS interface component (232), communication between said at least one MODBUS interface module (218) and said plurality of MODBUS based devices (228); and
providing by at least one EDU interface component (234), communication between said EDU interface module (220) and said plurality of EDU devices (230).