Integrated advanced control blocks in process control systems

A process control element adapted to be used as a portion of a process control routine implemented on a processor to control a process, the process control element comprising:

• a computer readable medium;
• an advanced control function block stored on the computer readable medium and adapted to be executed on the processor including,
• a first plurality of inputs, wherein each input is adapted to receive a different one of a set of process parameters;
• a second plurality of outputs, wherein each output is adapted to be communicatively coupled to a different process input for controlling the set of process parameters;
• a waveform generator adapted to generate process excitation waveforms at each of the plurality of outputs;
• and
• a data collection unit adapted to coordinate the collection of data representing signal values at each of the plurality of inputs when the waveform generator generates the process excitation waveforms at each of the plurality of outputs.

A method of developing an advanced control element for use in a process control routine that controls a process, the method comprising the steps of:

• providing an advanced control element having a first plurality of control inputs adapted to receive process outputs of the process and having a second plurality of control outputs adapted to provide control signals to process inputs of the process;
• communicatively connecting the advanced control element within the process control routine;
• using the advanced control element to provide excitation waveforms to each of the process inputs;
• using the advanced control element to collect data reflecting the response of each of the process outputs to the excitation waveforms;
• creating a process model from the collected data;
• developing advanced control logic parameters from the process model;
• and
• placing the advanced control logic parameters within the advanced control element for use by the advanced control element to control the process.

An advanced control element development system adapted to develop an advanced control element for use in a process control routine that is executed within a process control system, the advanced control element development system including:

• a computer readable medium;
• a first routine stored on the computer readable medium and adapted to be executed on a processor that creates an advanced control element having a first plurality of control inputs adapted to receive process outputs and having a second plurality of control outputs adapted to provide control signals to process inputs;
• a second routine stored on the computer readable medium and adapted to be executed on a processor that enables a user to communicatively connect the advanced control element within the process control routine;
• a third routine stored on the computer readable medium and adapted to be executed on a processor that uses the advanced control element to provide excitation waveforms to each of the process inputs;
• a fourth routine stored on the computer readable medium and adapted to be executed on a processor that uses the advanced control element to collect data reflecting the response of each of the process outputs to the excitation waveforms;
• a fifth routine stored on the computer readable-medium and adapted to be executed on a processor that creates a process model from the collected data;
• a sixth routine stored on the computer readable medium and adapted to be executed on a processor that develops advanced control logic parameters from the process model;
• and
• a seventh routine stored on the computer readable medium and adapted to be executed on a processor that places the advanced control logic parameters within the advanced control element to enable the advanced control logic element to control the process.

A method of using a multiple-input/multiple output advanced control element capable of controlling a process, wherein the advanced control element was is based on a process model developed for the process, the method comprising the steps of:

• generating a process simulation element from the process model;
• communicatively connecting the process simulation element to the advanced control element;
• and
• using the advanced control element to control the process simulation element.