Method for operating a production device with a modular design

Abstract

A method for operating a production facility with a modular design. The present invention relates to a method for operating a production facility (1) for producing chemical and / or pharmaceutical products, the production facility having process modules (2) that are independently controlled and connected to one another for production engineering purposes, wherein for each process module (2), the amount of material that is present in and to be processed by this process module (2) is continuously or discretely detected and compared with a specified amount limit value, and wherein when the amount of the material that is present in and to be processed by this process module (2) is less than or greater than the amount limit value, the mass inflow into the corresponding process module (2) is increased or decreased, wherein the mass inflow is simultaneously the mass outflow from another process module (2) that is upstream of this process module (2) for production engineering purposes, or when the amount of the material that is present in and to be processed by this process module (2) is greater than or less than the amount limit value, the mass outflow from the corresponding process module (2) is increased or decreased, wherein the mass outflow is simultaneously the mass inflow to another process module (2) that is downstream of this process module (2) for production engineering purposes.

Description

[0001] This application is a divisional application of a patent application with an application date of December 16, 2014, an application number of 201480069892.9, and an invention-creation title of "Method for Operating a Production Facility with a Modular Design".

[0002] The work leading to this invention has been funded by the grant agreement No. 228867 as part of the EU's Seventh Framework Programme RP7 / 2007 - 2013.

[0003] The present invention relates to a method for operating a production facility for producing chemical and / or pharmaceutical products, the production facility having process modules which are connected to one another for production purposes and are autonomous for regulation purposes.

[0004] The present invention also relates to a production facility for producing chemical and / or pharmaceutical products.

[0005] In order to produce a specific chemical and / or pharmaceutical product, it is necessary to provide a production facility with a unique equipment structure in order to be able to carry out the processing steps required accordingly in the individual process sections according to process engineering. If there is no longer a need to produce this specific product, the production facility is usually dismantled again in order to be able to build another production facility with a unique equipment structure, which can be used to produce another chemical and / or pharmaceutical product at the same location. The construction and dismantling of the production facility are very time-consuming and costly. There is thus a constant need to reduce the effort associated with producing different chemical and / or pharmaceutical products.

[0006] To avoid this problem, the production facility can be built from individual process modules in a modular manner, the individual process modules being able to be connected to one another for processing purposes and being autonomous for regulation purposes. However, since the regulation concepts used in traditional production facilities cannot be easily transferred to a production facility built from process modules (which are autonomous for regulation purposes) in a modular manner, such a production facility requires novel regulation concepts.

[0007] The object of the present invention is to provide a regulation concept for a production facility for producing chemical / pharmaceutical products, the production facility having process modules which are connected to one another for production purposes and are autonomous for regulation purposes.

[0008] This object is achieved by a method with the features of claim 1 of the patent and a production facility with the features of claim 4 of the patent. Preferred refinements of the present invention are stated in the dependent claims, and the dependent claims, either individually or in any desired combination with one another, can each constitute aspects of the present invention.

[0009] In claim 1 of the patent, a method for operating a production facility for producing chemical and / or pharmaceutical products is proposed, the production facility having process modules which are connected to one another for production purposes and are autonomous for regulation purposes, wherein, for each process module, the quantity of material present in and to be processed by this process module is detected continuously or discretely and compared with a specified limit value of this quantity, wherein

[0010] - if the quantity of material present in and to be processed by this process module is less than or greater than the limit value of this quantity, then the mass inflow into the respective process module is increased or decreased, which mass inflow is simultaneously the mass outflow of another process module which is connected upstream of this process module for production purposes, or

[0011] - if the quantity of material present in and to be processed by this process module is greater than or less than the limit value of this quantity, then the mass outflow from the respective process module is increased or decreased, which mass outflow is simultaneously the mass inflow of another process module which is connected downstream of this process module for production purposes. Within the scope of the present invention, the terms "limit value of the quantity" and "setpoint value of the quantity" can be used synonymously.

[0012] If the mass inflow into a respective process module is increased when the amount of material present in and to be processed by this process module is less than a limit value of this amount, and this mass inflow is at the same time the mass outflow of another process module which is connected upstream of this process module for production purposes, then the production device or its process module operates on the basis of a regulation concept known from production engineering as the pulling principle. On the other hand, if the mass outflow from a respective process module is increased when the amount of material present in and to be processed by this process module is greater than a limit value of this amount, and this mass outflow is at the same time the mass inflow of another process module which is connected downstream of this process module for production purposes, then the production device or its process module operates on the basis of a regulation concept known from production engineering as the pushing principle. Thus, in the case of the pulling principle, the driving force for the activity originates from the process module connected downstream of the process module, whereas, in the case of the pushing principle, the driving force for the activity originates from the process module connected upstream of the process module. The essence of the invention is that all process modules of the production device operate consistently on the basis of the pulling principle or the pushing principle. If not all process modules of the production device operate consistently on the basis of the pulling principle or the pushing principle, these process modules will be disadvantageous to each other. It is also not advisable to regulate the outflow of an upstream process module independently of the inflow of the process module connected downstream of the upstream process module.

[0013] Process modules which can be connected to each other for production purposes and are autonomous for regulation purposes can be designed as units which can be transported as a whole; can be transported to a desired production site where a production device with a corresponding assembly of a modular structure is intended to be established; and can be transported away from this site after the desired production has ended. This enables easy reuse of the individual process modules at different production sites in a way that reduces production costs. For this purpose, the process module can have a housing which enables the process module to be easily transported, and at least one process component for performing a desired process step is arranged in the housing, and the housing dimensions can be standardized.

[0014] In a production site, process modules can be connected (preferably via standardized connectors) to a permanently installed communication network and to a supply network, which can be used to supply the process modules with materials and / or energy and / or materials can be delivered into the supply network, such that at least one batch chemical reaction and / or continuous production can be carried out in a substantially autonomous manner using the process modules. The supply network can be used to transport solid, liquid and / or gaseous materials or mixtures of materials, which can exist especially in single-phase or multiphase form, such as suspensions or emulsions. For example, the supply network can have a compressed air line to supply compressed air; a water supply line to supply water; an electrical line to supply electrical energy; a material line to supply starting materials and / or auxiliary materials and / or to discharge products, by-products and / or waste; a cooling line to supply cold or to dissipate heat and / or a heating line to supply heat or to remove cold. Various wired or wireless communication networks can be considered as the communication network. Standardized information exchange between process modules connected to the communication network can be carried out via the communication network.

[0015] Additionally or alternatively, energy storage that can be connected to the supply network and / or storage containers for liquid, solid and / or gaseous materials can be provided inside the housing of the process module, such that chemical reactions can occur autonomously and independently of external supply. The process module can have functions such as heating, cooling, mixing, separating, controlling pressure, ventilation and / or discharging, which enable chemical reactions to be carried out and reaction conditions to be controlled.

[0016] According to an advantageous refinement, in order to detect the amount of material present in at least one process module and to be processed by this process module, the filling level in this process module is detected. This represents a simple and feasible way of detecting the amount of material present in the process module and to be processed by the process module by means of a suitable filling level sensor. It is also possible to carry out the detection of the amount of material present in each process module and to be processed by this process module by detecting the filling level in the process module.

[0017] According to a further advantageous refinement, in order to detect the amount of material present in at least one process module and to be processed by this process module, the pressure in this process module is detected. This can be provided as an alternative to the last-mentioned refinement or additionally added to the last-mentioned refinement to obtain redundant information. This refinement also represents a simple and feasible way of detecting the amount of material present in the process module and to be processed by the process module by means of a suitable pressure sensor. It is also possible to carry out the detection of the amount of material present in each process module and to be processed by this process module by detecting the pressure in the process module.

[0018] Claim 4 of the patent proposes a production device for producing chemical and / or pharmaceutical products, which has at least two process modules. The at least two process modules can be connected to each other for production purposes and are autonomous for regulation purposes. Each process module has its own electronic device, in particular a control and / or regulation device. The electronic device is configured to continuously or discretely detect the amount of material that is present in the corresponding process module and to be processed by this process module, and compare this amount with a specified limit value of this amount. Each electronic device is also configured to:

[0019] - If the amount of material that is present in this process module and to be processed by this process module is less than or greater than the limit value of this amount, then actuate the inflow of the corresponding process module to increase or decrease the mass inflow into this process module. This inflow is simultaneously the outflow of another process module, and the other process module is connected immediately upstream of this process module for production purposes, or

[0020] - If the amount of material that is present in this process module and to be processed by this process module is greater than or less than the limit value of this amount, then actuate the outflow of the corresponding process module to increase or decrease the mass outflow from this process module. This outflow is simultaneously the inflow of another process module, and the other process module is connected immediately downstream of this process module for production purposes.

[0021] The advantages and embodiments mentioned above regarding this method are correspondingly associated with this production device.

[0022] Each of the process modules can be changed from the pull principle to the push principle, or vice versa. Alternatively, it is possible that each of the process modules integrated in the corresponding production device is automatically and consistently changed on its own. This may additionally make it necessary to redesign the way in which the process modules are regulated, for example, the way in which the internal buffer network of the process modules is regulated.

[0023] Each electronic device of the process module can be connected to the communication network mentioned above for communication purposes. When the corresponding process module is connected to the communication network, the electronic device preferably detects, and after that, the electronic device automatically provides an identification signal to the communication network. For example, the type to which the process module belongs is made clear by this signal.

[0024] Each electronic device can be set to control and / or regulate the corresponding process module for a specific process segment of the production independently. In this case, "independently" means that the process segment is executed using the process module, and the process segment or a part of the process segment does not have to be controlled and / or regulated by a device remote from the process module for this purpose. Thus, the process module can operate autonomously accordingly.

[0025] The electronic device can also be set in such a way that the process modules connected to the communication network for communication purposes can communicate with each other automatically, for example, in such a way that at least one process module automatically requests information from at least one other process module. In particular, if the process modules connected to the communication network use their corresponding electronic devices to output an identification signal to the communication network, and this signal is received by the process modules already connected to the communication network, then automatic communication between the process modules is possible. Thus, the receiving process module can learn the address of the process module newly connected to the communication network. For example, in the case of process modules already connected to the communication network or their electronic devices, this can be a trigger for these process modules to also emit a corresponding identification signal to the communication network, which is then received by the process module newly connected to the communication network. The production equipment can have a plug-and-play function in this regard.

[0026] The information that can be requested from other process modules can include information in the form of given and / or expected process parameters, which are related to the process segment executed or to be executed by the process module providing this information. Then these process parameters can be used to control and / or regulate the requesting process module. This is particularly advantageous for subsequent process modules intended to further process the intermediate product produced by the previous process module in the temporarily previous process segment. For the further processing by the subsequent process module, it is quite important to know what characteristics the intermediate product produced by the previous process module has, so as to be able to determine what boundary conditions exist for producing the desired final product from the intermediate product and which must be complied with by the subsequent process module.

[0027] According to an advantageous improvement, at least one process module has at least one filling level sensor that detects the filling level of the material in this process module and is connected to the electronic device of this process module for communication purposes. The electronic device is set to determine the amount of material correspondingly present in the process module and to be processed by the process module based on the filling level of the material detected correspondingly by means of the filling level sensor. The advantages and embodiments mentioned in connection with the corresponding improvement of this method are correspondingly related to this.

[0028] According to a further advantageous refinement, at least one process module has at least one pressure sensor which detects the pressure in this process module and is connected for communication purposes to the electronic device of this process module, which electronic device is set up to determine, on the basis of the pressure detected accordingly by the pressure sensor, the amount of material present accordingly in the process module and to be processed by this process module. The advantages and embodiments mentioned in connection with the corresponding refinement of the method are also correspondingly relevant here.

[0029] A further advantageous refinement provides that on each line which forms the outflow of the upstream process module and at the same time forms the inflow of the process module connected downstream of this process module, at least one electrically activatable valve is arranged, which is connected for communication purposes to the electronic device of the upstream process module or the downstream process module. This makes it possible to regulate in a simple manner the outflow of material leaving the process module or the inflow of material entering the process module.

[0030] The invention is explained below by way of example with the aid of preferred exemplary embodiments, with reference to the drawings, and the features specified below, either on their own or in combination with one another, can each form aspects of the invention. In the drawings:

[0031] Figure 1 shows a schematic illustration of an exemplary embodiment of a production facility according to the invention, and

[0032] Figure 2 shows a schematic illustration of a further exemplary embodiment of a production facility according to the invention.

[0033] In Figure 1Shown is an exemplary embodiment of a production facility 1 for the production of chemical and / or pharmaceutical products according to the invention. The material flow is indicated by the arrow 7. The production facility 1 comprises n process modules 2 which are connected to one another for production purposes and are autonomous for regulation purposes. Each process module 2 has an electronic device 3, in particular a control and / or regulation device, which is set up to continuously or discretely detect the amount of material present in the respective process module 2 and to be processed by this process module 2, and to compare this amount with a specified limit value of this amount. Each electronic device 3 is also set up such that if the amount of material present in this process module 2 and to be processed by this process module 2 is less than the limit value of this amount, then the inflow of the respective process module 2 is actuated to increase the mass inflow into this process module 2, which inflow is at the same time the outflow of another process module 2 which is connected upstream of this process module 2 for production purposes. Thus, the production facility 1 or its process modules 3 operate according to the pull principle. In order to be able to correspondingly increase the respective inflow, an electrically activatable valve 5 is arranged on each line 4 which forms the outflow of the upstream process module 2 and at the same time forms the inflow of the process module 2 connected downstream of this process module 2, which valve 5 is connected to the electronic device 3 of the downstream process module 2 for communication purposes.

[0034] Each process module 2 also comprises a filling level sensor 6 which detects the filling level of the material in this process module 2 and is connected to the electronic device 3 of this process module 2 for communication purposes, and the electronic device 3 is set up to determine the amount of material present in the process module 2 and to be processed by the process module 2 by means of the filling level of the material detected by the filling level sensor 6. Alternatively or additionally, each process module 2 can have a pressure sensor (not shown) which detects the pressure in this process module 2 and is connected to the electronic device 3 of this process module 2 for communication purposes, and the electronic device 3 is set up to determine the amount of material present in the process module 2 and to be processed by the process module 2 by means of the pressure detected by the pressure sensor. For this purpose, each electronic device 3 can have a microprocessor and a suitable storage medium.

[0035] Figure 2 A schematic illustration shows a further exemplary embodiment of the production facility 1 according to the invention. This production facility 1 differs from Figure 1The exemplary embodiment shown, in particular, is that each electronic device 3 is arranged to actuate the outflow of the corresponding process module 2 to increase the mass outflow from this process module 2 when the amount of material present in this process module 2 and to be processed by this process module 2 is greater than the limit value of this amount, and this outflow is simultaneously the inflow of another process module 2, and the other process module 2 is connected downstream of this process module 2 for production purposes. An electrically activatable valve 5 is arranged on each line 4 that forms the outflow of the upstream process module 2 and simultaneously forms the inflow of the process module 2 connected downstream of this process module 2, and it is connected to the electronic device 3 of the upstream process module 2 for communication purposes.

Claims

1. A production device (1) for producing chemical and / or pharmaceutical products, having at least two process modules (2), which can be connected to each other for production purposes and are autonomous for regulation purposes, wherein, Each process module (2) has: a housing; at least one process component arranged in the housing for performing a desired process step; an electronic device (3) which is set up to continuously or discretely detect the amount of material present in the respective process module (2) and to be processed by this process module (2), and to compare the amount of material with a limit value of the amount; at least one electrically activatable valve (5) which is arranged in the outflow line of each process module (2) and is connected to the electronic device (3) of the respective process module (2) for communication purposes; wherein each electronic device (3) is set up to control and / or regulate the respective process module to independently carry out the production of the respective process step, and each electronic device (3) is further set up to: actuate the outflow of the respective process module (2) to increase or decrease the mass outflow from this process module (2) if the amount of material present in this process module (2) and to be processed by this process module (2) is greater than or less than the limit value of the amount, the outflow being at the same time the inflow of a further process module (2) which is connected downstream of this process module for production purposes; wherein the subsequent process module (2) of the at least two process modules (2) is set up to carry out the following steps: automatically request information from the preceding process module (2), the information comprising information in the form of relevant given or expected process parameters of the process step carried out or to be carried out by the preceding process module (2); further process the information to determine what properties the intermediate product produced by the preceding process module (2) has, in order to determine what boundary conditions exist for producing the desired final product from the intermediate product and which must be observed by the subsequent process module (2).

2. The production equipment (1) according to claim 1, characterized in that, At least one process module (2) has at least one fill level sensor (6) which detects the fill level of the material in this process module (2) and is connected to the electronic device (3) of this process module (2) for communication purposes, the electronic device (3) being set up to determine the amount of material present in the process module (2) and to be processed by the process module (2) by means of the fill level of the material detected by means of the fill level sensor (6).

3. The production device (1) according to claim 1 or 2, characterized in that, At least one process module (2) has at least one pressure sensor which detects the pressure in this process module (2) and is connected to the electronic device (3) of this process module (2) for communication purposes, the electronic device (3) being set up to determine the amount of material present in the process module (2) and to be processed by the process module (2) by means of the pressure detected by means of the pressure sensor.

4. A production device (1) for producing chemical and / or pharmaceutical products, having at least two process modules (2), which can be connected to each other for production purposes and are autonomous for regulation purposes, wherein, Each process module (2) has: a housing; At least one process component arranged within the housing for performing a desired process segment; an electronic device (3) configured to continuously or discretely detect the amount of material present in the respective process module (2) and to be processed by this process module (2), and to compare the amount of material with a limit value of the amount, At least one electrically activatable valve (5) arranged on the inflow line of each process module (2) and connected to the electronic device (3) of the respective process module (2) for communication purposes; wherein each electronic device (3) is configured to control and / or regulate the respective process module (2) to independently perform the production of the respective process segment, and each electronic device (3) is further configured to: if the amount of material present in this process module (2) and to be processed by this process module (2) is greater than or less than the limit value of the amount, then actuate the inflow of the respective process module (2) to increase or decrease the mass inflow from this process module (2), the inflow being simultaneously the outflow of another process module (2) connected immediately upstream of this process module for production purposes; wherein the subsequent process module (2) of the at least two process modules (2) is configured to perform the following steps: automatically request information from the preceding process module (2), the information including information in the form of relevant given or expected process parameters of the process segment performed or to be performed by the preceding process module (2); further process the information to determine what characteristics the intermediate product produced by the preceding process module (2) has in order to determine what boundary conditions exist for producing the desired final product from the intermediate product and which must be complied with by the subsequent process module (2).

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