Customized logic engineering for industrial modular factories

Abstract

The present invention relates to a method for custom logic design in an industrial modular plant for executing a production process, comprising the following steps: receiving process data for a production process using at least one physical process module; determining a custom process topology by: - ​​selecting at least one module type package MTP associated with at least one corresponding physical process module from a database based on the received process data, wherein the module type package is a digital representation of the corresponding physical process module; - selecting at least one expander unit representing a logical function of the production process from the database based on the received process data; - determining a connection between at least one expander unit and at least one MTP; - setting properties of at least one expander unit based on the received process data; and determining an extended control scheme for controlling the dynamic behavior of the production process using the determined custom process topology.

Description

Technical Field

[0001] The present invention relates to the field of engineering industrial modular plants. Background Art

[0002] Today, modular plants are engineered at two levels. First, a process topology representing the required process equipment and material flows is created by instantiating and connecting module representations derived from the modular type package (MTP). Then, the process orchestration (POL) layer is designed to control the dynamic behavior of processes that transform and transport materials through individual process steps. While reducing engineering complexity, this approach also limits the depth and fidelity of process model integration. Properties of the plant topology (such as actual pipe lengths or diameters) cannot be considered. Unit or range differences between connected modules cannot be converted within the boundaries of modular automation standards. User-friendly or proven design methods for POLs (such as sequential function charts (SFCs)) cannot be used for highly complex process recipes. Designing POLs using mature (full-fledged) IEC 61131 programming defeats the simplicity and speed inherent in modular automation. Summary of the Invention

[0003] Therefore, the object of the present invention is to provide an improved method for engineering industrial modular plants that overcomes the aforementioned limitations. This object is achieved by the subject matter of the independent claims. Further preferred embodiments are evident from the dependent patent claims.

[0004] According to the present invention, a method for custom logic engineering in an industrial modular factory for executing a production process includes the following steps. In a first step, process data for a production process is received using at least one physical process module. In a second step, a custom process topology is determined by: selecting at least one module type package (MTP) associated with at least one corresponding physical process module from a database based on the received process data, wherein the module type package is a digital representation (or, in other words, a digital twin) of the corresponding physical process module; selecting at least one extender unit from the database based on the received process data, which represents a logical function of the production process; determining a connection between the at least one extender unit and at least one MTP; and setting properties of the at least one extender unit based on the received process data. In a third step, an extended control scheme for controlling the dynamic behavior of the production process is determined using the determined custom process topology.

[0005] A custom process topology represents the required process equipment (e.g., physical modules) and creates material flows by instantiating and connecting module representations derived from modular type packages (MTPs) and from extender units. The process orchestration layer (POL) is then configured to control the dynamic behavior of the production process, transforming and transporting materials through individual process steps, based on the custom process topology. In modular engineering design tools, the custom process topology is represented by a diagram on which different MTPs or process modules, as well as different extender units, are arranged and interconnected to model or represent the production process.

[0006] As used herein, the term "extended control" refers to process data of a production process that is not represented by an MTP in a process topology. In a custom process topology, the process data represented by the MTP is extended with additional process data represented by extender units. Extended control preferably includes relationships between different materials and / or physical modules that cannot be represented or modeled by known MTPs.

[0007] As used herein, the term "production process" describes the processing of at least one starting material to provide a final material. This production process typically includes steps such as mixing, heating, cooling, pressurizing and / or storing different materials or intermediate products.

[0008] As used herein, the term "process data" refers to information about the production process to be executed by an industrial modular plant. Preferably, process data is referred to as a process recipe. Process data is the basis for designing and / or controlling production processes, particularly for use by automation systems and / or modularization engineers.

[0009] In other words, the expander unit expands the representation of the production process on a topological level, in particular by means of data or control codes.

[0010] In an example, the expander unit expands functionality of the MTP that has not or cannot yet be integrated into the MTP. Preferably, similar to the MTP, the logic function expander is represented as an element in a custom process topology that is loaded into a modular engineering design tool, for example, used by a modular engineer.

[0011] Preferably, a modular type package (MTP) is a virtual model of a physical process module. Therefore, an MTP is also referred to as a process module. It contains all necessary information for integrating the module into a modular plant, such as communication, services, a human-machine interface (HMI) description, and maintenance information. In other words, an MTP represents a description of a physical process module, based on which a digital representation of the physical process module can be instantiated.

[0012] Preferably, the logical functions of the production process are instantiated by the expander unit based on an existing function library, in particular within a distributed control system DCS.

[0013] In other words, the customized process topology involves a combined plant topology (or in other words, equipment topology) that combines physical process modules and logic functions. Thus, logic functions are added to the modular engineering design based on the MTP on top of the equipment topology.

[0014] Preferably, the method is a computer-implemented method.

[0015] Preferably, the step of selecting the MTP and / or expander unit comprises: automatically instantiating the MTP / expander unit, in particular based on the process data; and selecting the MTP / expander unit by a modularization engineer and / or automatically based on the process data.

[0016] Preferably, the method is used in a modular engineering design tool (or in other words, a choreography designer program and engineering design tool) configured for implementing complex choreography schemes without control code programming. Thus, digital representations can be handled efficiently.

[0017] Preferably, the MTP and expander units are known assets, especially for modular engineering design tools.

[0018] Preferably, a distributed control system DCS engineering design project is set up to host the control solution implementation of a modular industrial plant. In other words, the method is used in a modular automation engineering design project for controlling a production process.

[0019] Preferably, the setting properties of the at least one expander unit are added to the control code library of the DCS for use in setting properties of the at least one expander unit in the future.

[0020] Preferably, all services and signals from the custom process topology are also available to the process.

[0021] Thus, services and signals from the MTP and expander units are seamlessly connected during a method of custom logic engineering for an industrial modular plant.

[0022] Design problems can thus be solved at the process topology level. In other words, logical functions such as, for example, unit conversions can be used and configured directly from within the process topology editor of the modular engineering tool, in particular without programming.

[0023] Preferably, setting the property of the at least one expander unit comprises determining a parameterization for the at least one expander unit.

[0024] As used herein, the term "parameterization" refers to the adjustable settings provided by an expander unit. Those settings can be adjusted based on process data. This allows for the design of templates for different expander units that can be parameterized based on process data. For example, there are expander units for T-sections of pipes. However, different pipe lengths within a T-section can be accommodated by parameterizing the expander unit. Thus, in a customized process topology, a universal expander unit for T-sections can be introduced, where the expander unit is parameterized based on process data.

[0025] This therefore allows for a simple and fast representation of complex production processes in a modular engineering tool.

[0026] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0027] Advantageously, since all extensions (although only logical functions) are handled like MTPs, users (especially process experts) can use the described method in the same natural way standardized by modular engineering. This allows users to achieve a higher level of proficiency.

[0028] The method thus allows complex orchestrations to be implemented without control code programming, enabling customers to create more complex or more demanding process recipes simply by expanding the process topology in a natural way. This allows the coverage of modular automation to be expanded without compromising the simplicity of the modular engineering concept.

[0029] In other words, the general design principles of modular engineering (especially the use of configurable modules rather than the usual monolithic engineering) are applied. In other words, the expander unit is applicable within modular automation standards (such as VDI 2658) and is therefore applicable for custom logic engineering in industrial modular plants.

[0030] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0031] In a preferred embodiment, at least one extender unit comprises at least one virtual module type package vMTP which models the dynamic properties of a multi-point material flow through the passive device.

[0032] Preferably, the passive equipment comprises pipes that connect the physical modules of the industrial modular plant and transport materials.

[0033] Preferably, within a custom process topology, the vMTP is represented as a box that behaves like an MTP. The vMTP provides material inputs and outputs, as well as signals (such as control signals or trigger signals). The vMTP can be parameterized to tailor its behavior within the custom process topology to the plant topology engineering design intent, or in other words, to the process data.

[0034] The extender unit thus provides a parameterizable model which models additional functionalities of the production process, in particular for use in customized process topologies.

[0035] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0036] In a preferred embodiment, at least one expander unit comprises at least one dedicated logic function.

[0037] Preferably, the dedicated logic function is configured to perform any algorithmic calculations. As an example, the dedicated logic function provides a logical AND of two Boolean signals, thereby comparing the actual level of a tank with a reference level to create a Boolean signal that can be used as a trigger in the POL. In another example, the dedicated logic function provides a logical AND / OR between modules to achieve interlocking between modules, such as a reactor module is only allowed to pump through the next two parallel filtration modules, or one of them is ready. In another example, the dedicated logic function provides a conversion box to connect two temperature values ​​between modules, one in ° C and one in K. In another example, the dedicated logic function provides a PID controller to control the temperature in a reactor module by switching a simple heating module on / off or setting a certain value, especially if no PID controller itself is available in the module.

[0038] In a custom process topology, wires only transmit signals and states, but boxes representing dedicated logic functions can be parameterized.

[0039] The extender unit thus provides a parameterizable model which models additional functionalities of the production process, in particular for use in customized process topologies.

[0040] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0041] In a preferred embodiment, the at least one logic function comprises a logic gate function and / or a single-bit conversion.

[0042] Preferably, the logic gate function includes a function of a logic gate such as AND, OR, XOR, etc.

[0043] In a preferred embodiment, at least one expander unit comprises at least one smart connector that models the dynamic properties of the material flow.The at least one smart connector is used for connection between at least one vMTP and at least one MTP.

[0044] For example, a smart connector models the delay in the flow of a fluid based on the length of the pipe. Annotating a smart connector with physical pipe properties (such as length or diameter) allows calculation of the expected pressure, flow delay, or amount of material flow within a pipe based on the output flow of a material-providing module, or the flow within a pipe based on the output pressure of a material-providing process module.

[0045] Smart Connectors represent material flows within a custom process topology. They can also be parameterized or provide signals. For example, they can set parameters for other expansion units (such as vMTPS).

[0046] The extender unit thus provides a parameterizable model which models additional functionalities of the production process, in particular for use in customized process topologies.

[0047] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0048] In a preferred embodiment, when determining the expansion control solution, at least one expander unit is visualized and represented, in particular in the engineering data, as is at least one MTP.

[0049] The expander unit provides services, material flow connections, and I / O signals just like any process module that represents a physical module.

[0050] Thus, the expander unit provides a parameterizable model that models additional functionality of a production process that behaves like an MTP in a customized process topology and / or POL.

[0051] Thus, an improved method for custom logic engineering in industrial modular plants is provided.

[0052] In a preferred embodiment, the extended control scheme is determined in the process orchestration layer POL, thereby making the extended control of the production process visible.

[0053] In other words, as long as the properties of the expander unit (e.g., configuration, services, and / or status) conform to the MTP, the properties of the expander unit will be visible at the POL layer. This allows for expanded control of the POL as additional features are added at the POL layer. However, the POL itself is not changed when an expander unit is introduced.

[0054] Preferably, the POL is a layer above the custom process topology.

[0055] Preferably, determining the extended control scheme includes creating an extended POL code in the DCS.

[0056] In POL, the expander unit provides signals such as input triggers, status and services.

[0057] In a preferred embodiment, the method comprises the step of implementing the control scheme using a Sequential Flowchart SFC, in particular on a POL.

[0058] As described, providing an expander unit that can be used in a custom process topology allows the use of relatively simple SFCs in POLs. Thus, relatively complex production processes can be modeled and controlled without significantly increasing the complexity of the task.

[0059] Furthermore, SFCs typically cannot provide real-time processing. Consequently, continuous logic or control cannot be represented by SFCs. Expander units allow for the representation of interlocks between MTPs and SFCs. Furthermore, expander units allow for the implementation of fast-reaction triggers that cannot be represented by relatively slow SFCs. Therefore, using expander units, real-time processing can be implemented using SFCs.

[0060] In a preferred embodiment, the method comprises the step of operating the modular plant using a control scheme.

[0061] Preferably, the extended POL code is compiled and downloaded for operation of the industrial modular plant.

[0062] In a preferred embodiment, determining the at least one expander unit comprises loading the at least one expander unit from a library and / or obtaining the at least one expander unit from model data (particularly CAD data).

[0063] Due to the parameterization possibility of the expander unit, a universal expander unit can already be stored in a library and only be selected therefrom by the automation system or modularization engineer. Alternatively, the expander unit can also be determined directly based on model data, in particular provided by the process data.

[0064] Preferably, the library is loaded by the DCS into a modular engineering design tool available in particular for custom process topologies and POLs in order to make the extender unit types available together with the MTP.

[0065] In a preferred embodiment, determining the at least one expander unit comprises extracting the at least one expander unit from a process flow diagram, in particular a piping and instrumentation diagram.

[0066] Typically, MTP cannot be used to fully represent all the information in a process flow diagram. Using expander units, the process flow diagram is fully represented at the topology level. This allows modular engineering design techniques to be used to fully represent the process as defined in the process flow diagram.

[0067] Preferably, the MTP and the expander unit are automatically extracted from the process flow diagram, in particular by means of a computer-implemented extraction algorithm.

[0068] For example, a "System Control Diagram" according to NORSOK standard I-005 is imported. This already includes the logic in the form of a piping and instrumentation diagram. The extraction uses a specific export format such as AutomationML, for example.

[0069] According to aspects of the invention, a customized process topology comprises at least one expander unit and at least one MTP as determined by the method as described herein.

[0070] Thus, in the modular engineering tool, a customized process topology extends a known process topology by means of at least one extender unit, thereby allowing a more detailed representation of the production process without significantly increasing the complexity of the engineering task.

[0071] According to an aspect of the invention, there is provided the use of an extended control solution as described herein as determined by the method for controlling the dynamic behavior of a production process of an industrial modular plant.

[0072] According to an aspect of the invention, there is provided a computer program comprising instructions which, when said program is executed by a computer, cause the computer to perform the method as described herein.

[0073] According to an aspect of the invention, there is provided a computer readable data carrier having stored thereon a computer program as described herein.

[0074] The present invention also relates to a computer program product comprising computer program code for controlling one or more processors of an apparatus adapted to be connected to a communication network and / or configured to store a standardized configuration representation, in particular to a computer program product comprising a computer-readable medium in which the computer program code is embodied.

[0075] Preferably, the functional modules and / or configuration mechanisms are implemented as programming software modules or procedures, respectively; however, those skilled in the art will appreciate that the functional modules and / or configuration mechanisms may be fully or partially implemented in hardware. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] The subject matter of the invention will be explained in more detail in the following text with reference to preferred exemplary embodiments illustrated in the accompanying drawings, in which:

[0077] Figure 1 Schematically illustrates a customization process topology according to a first embodiment;

[0078] Figure 2 schematically illustrates a customization process topology according to a second embodiment; and

[0079] Figure 3 A method for custom logic engineering of industrial process topologies is schematically illustrated.

[0080] The reference symbols used in the drawings and their meanings are listed in summary form in the list of reference symbols. In principle, identical components are provided with the same reference symbols in the drawings. DETAILED DESCRIPTION

[0081] Figure 1 A schematic diagram of a customized process topology 10 according to a first embodiment is shown. The customized process topology 10 relates to an industrial modular plant to be configured to perform a production process. The industrial modular plant includes at least one physical process module, such as a heating module, a mixing module, or a cooling unit. In this case, the industrial modular plant to be controlled or designed and controlled includes three physical process modules. An MTP for each physical process module is selected from a database based on the corresponding process data. Thus, a first MTP 11, a second MTP 12, and a third MTP 13 are selected.

[0082] Furthermore, two expander units, a first vMTP 20 and a dedicated logic function 30, are selected from a database based on process data for the MTPs 11, 12, and 13 corresponding to the physical process modules of the industrial modular plant. The vMTP 20 represents a T-segment of a pipeline connecting the first MTP 11 and the third MTP 13. Therefore, the first MTP 11, the second MTP, the third MTP, and the first vMTP 20 are connected to a flow connector CF based on the process data. The flow connector CF represents a pipeline through which material is transferred from one MTP or vMTP to another. Because a T-segment of pipeline exists between the physical process modules represented by the first MTP 11 and the third MTP 13, the first vMTP, representing the T-segment, is accordingly connected by the flow connector CF. The dedicated logic function 30 represents a logical AND gate. The dedicated logic function 30 connects the first MTP 11, the second MTP 12, and the third MTP 13 via a logic connector CL. Therefore, the logical relationship between the logic signals of the three MTPs 11, 12, 13 can be engineered on a process topology level.Of course, the logic connector CL can also connect any expander unit or MTP.

[0083] Hence, a customized process topology 10 is provided which expands a known process topology by means of expander units 20, 30. Hence, an expanded control solution for controlling the dynamic behavior of a production process can be determined using the customized process topology 10 and a simple sequential function chart SFC.

[0084] Figure 2 A customized process topology 110 according to a second embodiment is schematically illustrated. In this case, customized process topology 110 describes a mixing module physically comprising two dosing modules, which are connected to a container module via a pipeline comprising a T-segment. The two mixing modules are represented by a fourth MTP 111 and a fifth MTP 112. The container module is represented by a sixth MTP 113. The three MTPs 111, 112, and 113 are connected to each other via flow connectors (in this case, smart connectors 40). The T-segment is represented by a second vMTP 120. Compared to a normal flow connector, the smart connector 40 provides additional properties (such as material flow). As indicated, the vMTP 120 provides logical functions related to the lengths of different portions of the T-segment. In this case, the first length L1 of the pipeline from the fourth MTP 111 is 1 meter long, the second length L2 of the pipeline from the fifth MTP 112 is 2 meters long, and the third length L3 of the pipeline from the sixth MTP 113 is 3 meters long. Therefore, the length of the T-shaped pipe is represented by vMTP 120. vMTP 120 includes a first input I1 and a second input I2 for receiving a smart connector 40. Therefore, vMTP 120 includes an output O for connecting vMTP 120 to sixth MTP 113 via smart connector 40. vMTP 120 also provides two binary signals (input trigger It1 and input trigger It2, which can be used in the SFC as trigger conditions for starting the metering service). In a similar manner, a mixing input Im is provided to enable or disable the mixing procedure implemented through the pipe. In the SFC, the mixing service is triggered according to the process recipe of the production process, followed by conditional checks on the trigger signals for starting the metering service of the metering module at the first input I1 and the second input I2.

[0085] This approach saves costs because, instead of complex process modules, more demanding process recipes can be implemented using only T-segments. Furthermore, no changes to metering or container process modules are required. Finally, extended control schemes can be implemented using standard SFC because, from an engineering perspective, the specificities of a production process can be described using the standardized concept of process modules.

[0086] The inserted T-segment can have an influence on the process recipe of the prior art, for example, so that the metering of one material is delayed compared to the other material in order to compensate for the different line lengths from the two metering modules into the container module.

[0087] Figure 3 A method for custom logic engineering in an industrial modular factory for executing a production process comprises the following steps. In a first step S10, process data for a production process is received using at least one physical process module. In a second step S20, a custom process topology 10 is determined through the following steps. In a first sub-step S21, at least one module type package (MTP) associated with at least one corresponding physical process module is selected from a database based on the received process data, where the module type package (11, 12, 13) is a digital representation of the corresponding physical process module. In a second sub-step S22, at least one expander unit (20, 30, 40) representing a logical function of the production process is selected from the database based on the received process data. In a third sub-step S23, a connection is selected between the at least one expander unit (20, 30, 40) and the at least one MTP (11, 12, 13). In a fourth sub-step S24, properties of the at least one expander unit (20, 30, 40) are set based on the received process data.

[0088] In a third step S30 , an extended control solution for controlling the dynamic behavior of the production process using the determined customized process topology 10 is determined.

[0089] Reference Symbols List

[0090] 10 Customizing process topology

[0091] 11 First MTP

[0092] 12 Second MTP

[0093] 13 Third MTP

[0094] 20 First vMTP

[0095] 30 dedicated logic functions

[0096] 40 Smart Connectors

[0097] CF Flow Connector

[0098] CL Logic Connector

[0099] 110 Custom Process Topology

[0100] 111 Fourth MTP

[0101] 112 Fifth MTP

[0102] 113 Sixth MTP

[0103] 120 Second vMTP

[0104] I1 First input

[0105] I2 Second input

[0106] O Output

[0107] L1 first length

[0108] L2 Second length

[0109] L3 third length

[0110] Im mixed input

[0111] It1 First input trigger

[0112] It2 Second input trigger

[0113] S10 First step

[0114] S20 Step 2

[0115] S21 First sub-step

[0116] S22 Second sub-step

[0117] S23 The third sub-step

[0118] S24 Fourth sub-step

[0119] S30 third step.

Claims

1. A method for custom logic engineering in an industrial modular factory for performing a production process, comprising the following steps: receiving (S10) process data for the production process using at least one physical process module; The customized process topology (10) is determined (S20) by, - selecting (S21) at least one module type package MTP (11, 12, 13) associated with at least one corresponding physical process module from a database based on the received process data, wherein the module type package (11, 12, 13) is a digital representation of the corresponding physical process module; - selecting (S22) at least one expander unit (20, 30, 40) from the database based on the received process data, which represents an expanded control of the production process; - determining (S23) a connection (CL, CF) between the at least one expander unit (20, 30, 40) and the at least one MTP (11, 12, 13); - setting (S24) properties of the at least one expander unit (20, 30, 40) based on the received process data; determining (S30) an extended control scheme for controlling the dynamic behavior of the production process using the determined customized process topology (10), Wherein, the at least one extender unit comprises at least one virtual module type packet vMTP (20) which models the dynamic properties of a multi-point material flow through the passive device.

2. The method according to claim 1, in, The at least one expander unit comprises at least one dedicated logic function (30).

3. The method according to claim 2, in, The at least one logic function (30) comprises a logic gate function and / or a single-bit conversion.

4. The method according to any one of claims 1 to 3, in, The at least one expander unit includes at least one smart connector (40) that models dynamic properties of the material flow; The at least one intelligent connector (40) is used for connection (CF) between the at least one vMTP (20) and the at least one MTP (11, 12, 13).

5. The method according to any one of claims 1 to 3, in, When determining (S20) the expansion control scheme, the at least one expander unit (20, 30, 40) is visualized and represented like the at least one MTP (11, 12, 13).

6. The method according to any one of claims 1 to 3, in, The extended control scheme is determined in a process orchestration layer POL, making the extended control of the production process visible.

7. The method of claim 6, comprising the steps of: The control scheme is implemented on the POL using a sequential flow chart (SFC).

8. The method according to any one of claims 1 to 3, comprising the steps of: The modular plant is operated using the control scheme.

9. The method according to any one of claims 1 to 3, wherein Determining at least one expander unit (20, 30, 40) includes: The at least one expander unit is loaded from a library and / or obtained from CAD data.

10. The method according to any one of claims 1 to 3, wherein Determining the at least one expander unit (20, 30, 40) comprises: The at least one expander unit (20, 30, 40) is extracted from a process flow diagram, in particular a piping and instrumentation diagram.

11. A customized process topology comprising at least one expander unit and at least one MTP as determined by the method according to any one of claims 1 to 10.

12. Use of an extended control solution as determined by the method according to any one of claims 1 to 10 for controlling the dynamic behavior of a production process of an industrial modular plant.

13. A computer program product comprising a computer program containing instructions which, when executed by a computer, cause the computer to perform the method according to any one of claims 1 to 10.

14. A computer-readable data carrier storing a computer program, the computer program comprising instructions which, when executed by a computer, cause the computer to perform the method according to any one of claims 1 to 10.

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