Process engineering plant and method for controlling a process engineering plant

Abstract

Process engineering plant (90) comprising several modules (1, 70, 80) and a higher-level plant control system (60), each of which (1, 70, 80) comprises: a. process engineering hardware (10) for carrying out a process engineering subprocess; b. a controller (20) for local control of the process hardware (10), wherein the controller (20) is configured to autonomously control the process hardware (10) and to bring it into a number of predetermined defined states; and wherein c. is assigned a defined command to bring it into one of the predetermined defined states; and wherein d. the control system (20) is set up to independently control a transition of the process hardware (10) between the predetermined defined states without external commands; and e. an external interface (22) of the controller (20), wherein the external interface (22) is configured to receive the defined commands corresponding to the predetermined defined states of the process hardware (10); wherein the external interface (22) is configured to communicate an operating screen (28) to the higher-level controller (60), wherein the operating screen (28) contains a description of the function of the module (1), the predetermined defined states and the defined commands, and wherein the operating screen (28) is designed such that the module (1) can be integrated into the software of the higher-level controller (60) as a pre-configured data module and is integrated into its control software by the higher-level controller as a pre-configured data module; and wherein the higher-level plant control (60) is designed to output defined commands that correspond to the specific defined states of the process hardware (10) of the modules (1, 70, 80).

Description

1. Field of the invention

[0001] The present invention relates to process engineering plants and their control systems. In particular, the present invention relates to modularly constructed process engineering plants. 2. State of the art

[0002] In the process industry, particularly in the chemical, pharmaceutical, and food manufacturing sectors, product demand is becoming increasingly difficult to predict and fluctuates regionally over short periods. Furthermore, the global availability of alternatives is leading to ever shorter product lifecycles.

[0003] Conventional production facilities are often not designed for these fluctuating product quantities. Continuously operated systems are usually optimized for a specific product quantity per unit of time and can only operate effectively at this production rate. Standard batch production systems are less efficient and require significant unproductive time, such as cleaning or changeover times.

[0004] When expanding or upgrading a system, it is usually necessary to reconfigure or reprogram the corresponding system control. This is a complex process that often takes about the same amount of time as a hardware upgrade. This is further complicated by potentially inadequate documentation of the existing control software or outdated control hardware that may not provide sufficient functionality for the new hardware.

[0005] Recent developments in the process industry focus on modular plant concepts, where the plant is built from individual prefabricated modules. Such concepts and their challenges are explored in a survey entitled "Modular Plant Design and Automation using the F 3 The project is described in the article "Process" by Dipl.-Ing. Sabine Mühlenkamp / Wolfgang Ernhofer, dated May 10, 2012. The integration of the modules into the control system is also considered an open question in this article.

[0006] Document DE 100 12 579 A1 relates to a process module for a processing station, a processing station itself, and a method for commissioning a processing station. The processing station has a control unit to which a program execution unit is assigned, on which a program controlling the process module is executed. The control unit also includes a program data management unit that coordinates the transfer of the program assigned to the process module from a program data memory to the program execution unit.

[0007] Document DE 10 2008 024 461 A1 concerns a packaging machine with multiple processing stations. The control of processing steps in one of the processing stations is carried out by the processing station control units, which are connected to a central control unit. A processing station is replaced and / or retrofitted by reading configuration parameters, whereby the central control unit and / or the processing station control unit are each designed in such a way that a replacement and / or retrofit of the processing station is automatically detected.

[0008] The object of the present invention is therefore to make process engineering plants more flexible with regard to their production rate, to accelerate plant planning and construction, and to provide suitable means and methods for this purpose. 3. Summary of the invention

[0009] The above problem is solved by a process engineering plant according to claim 1 and by a method for controlling a process engineering plant according to claim 10.

[0010] A module for a process plant comprises process hardware for carrying out a process subprocess, a controller for local control of the process hardware, wherein the controller is configured to autonomously control the process hardware and bring it into a number of specific defined states, and an external interface of the controller, wherein the external interface can receive a number of defined commands corresponding to the specific defined states of the process hardware.

[0011] A process plant is composed of several of these modules. If more production capacity is required, modules can be easily added to the plant and then perform specific subprocesses. For this purpose, the modules can assume a defined number of specific states. Since the controller of each module manages the process hardware locally and autonomously, and can bring it into any of the defined states, the control effort of the overall plant is minimized. A higher-level controller for the entire plant therefore only needs to send defined commands to an external interface of the module's controller so that it can move to and then assume one of its defined states. The higher-level controller can, for example, issue commands to start the subprocess, to change the module's operating mode, to pause, or to stop the subprocess.The module's internal control system then takes over the module's control autonomously, without external intervention, to achieve the defined states. The module's control system can therefore be provided, programmed, and configured by the module manufacturer, allowing the system manufacturer to create the control system for the entire system with very little effort.

[0012] Accordingly, when a production plant undergoes a hardware modification, the central, overarching control system of the entire plant only needs to issue "high-level" commands to the relevant modules, and the majority of the control effort is performed decentrally and autonomously in the individual modules.

[0013] To receive the defined "high-level" commands, the module has the aforementioned external interface for its controller. The external interface is not designed to receive commands that directly control actuators of the respective module. This control is the responsibility of the module's own controller.

[0014] Preferably, the external interface can only receive commands that correspond to specific, defined states of the process hardware. Accordingly, only these "high-level" commands can be received via the module's external interface. Other commands cannot be received and therefore cannot be processed by the module's control system.

[0015] The controller autonomously manages the transition of the process hardware between defined states without external commands. Control by a higher-level controller is not required. Therefore, the module is self-contained both in terms of hardware and control technology.

[0016] Preferably, no intermediate states of the process hardware can be controlled via the external interface. Therefore, only the defined states of the module can be controlled via the external interface, which minimizes the control effort for a higher-level controller.

[0017] Preferably, the external interface remains configured to issue defined commands to upstream, downstream, or parallel modules. This allows modules to control each other via horizontal communication. For example, an upstream module can start a downstream module when it has completed an intermediate product for further processing. Naturally, it is also possible for parallel modules to command each other or be commanded jointly.

[0018] Preferably, the external interface is configured to receive the defined commands from upstream or downstream modules. Similarly, for horizontal communication between modules, the external interface can also receive the defined commands from upstream, downstream, or parallel-connected modules.

[0019] Preferably, the external interface remains configured to receive the defined commands from a higher-level plant control system.

[0020] Preferably, the external interface remains configured to output data to a higher-level plant control system. The external interface can also output data to the plant control system, for example, signals indicating whether the respective defined state has been reached, whether the module is operating correctly, or whether a module malfunction has occurred.

[0021] A process plant preferably comprises several of the modules defined above. This allows the process plant to be easily expanded with additional modules, reduced in size, or converted to other products without requiring significant effort for overarching control system adjustments.

[0022] The process plant also features a higher-level plant control system for issuing defined commands that correspond to the specific defined states of the process hardware of the modules.

[0023] The above-mentioned tasks are also solved by a method for controlling a process plant, wherein the plant is composed of several modules and a higher-level plant control system, wherein the modules each have process hardware for carrying out a process subprocess, as well as a controller for local control of the process hardware and an external interface of the controller, wherein the external interface can receive a number of defined commands corresponding to a number of specific defined states of the process hardware, and the method comprises the following steps: a. Receiving through the external interface of a module a command from the number of defined commands for the respective module; b. autonomous control of the process hardware of a module by the corresponding control according to the received command, in order to bring the process hardware of the module into one of a number of defined states.

[0024] Because each module has its own controller and only needs to receive defined commands via its external interface, corresponding to a state from a set of predefined states of the module's process hardware, and the process hardware is then autonomously controlled by its respective controller to bring it into one of these predefined states, the advantages of a simplified control system configuration described above are realized. The overall system can thus be built very easily in a modular fashion, making the overall control system simple to create. Furthermore, modules can be added, removed, or replaced with other modules just as easily without requiring major reconfiguration or even reprogramming of the overall system's higher-level control software.

[0025] Preferably, the method further includes the step of receiving defined commands from upstream, downstream, or parallel modules by at least one of the modules.

[0026] Preferably, the method further includes the step of receiving defined commands from a higher-level controller by at least one of the modules.

[0027] Preferably, the method further includes the step of at least one of the modules issuing defined commands to upstream, downstream, or parallel modules. This enables horizontal communication between the modules of a system.

[0028] Preferably, the method further includes the step of at least one of the modules outputting signals to a higher-level controller. This enables vertical communication between the higher-level controller and the modules of a system.

[0029] The process further includes the step of at least one of the modules outputting a module-specific user interface to the higher-level controller. The user interface, which communicates the module's properties and control options to the higher-level controller during initial installation, further minimizes the programming effort of the higher-level controller's software. The module is integrated there as a pre-configured data module. The user interface includes, in particular, a description of the module's function, its defined states, its defined commands, and preferably a user interface and a graphical representation of the module. 4. Brief description of the drawings

[0030] Preferred embodiments of the present invention are described below with reference to the drawings which show: Fig. 1. A schematic view of a process plant with several modules; and Fig. 2. A flowchart of a procedure for controlling a process engineering plant. 5. Description of preferred embodiments

[0031] Preferred embodiments of the present invention are described in detail below with reference to the figures.

[0032] Fig. Figure 1 shows a process plant 90, which is composed of several individual modules 1, 70, 80 and possibly other modules not shown. The process plant 90 also has a higher-level control unit 60, which communicates with the individual modules 1, 70, 80 via a suitable bus 62.

[0033] Module 1 of the process plant 90 is representative of all modules 1, 70, and 80 of the process plant 90. It comprises process hardware 10 for carrying out a subprocess. In the example shown, the process hardware 10 includes, for instance, a reactor 30 with a mixer 40 driven by an electric motor 42. The reactor 30 also has an electric heating element 50 controlled by power electronics 52. The reactor 30 itself consists of a preferably closed vessel to which an inlet pipe 32 and an outlet pipe 34 are connected for filling and emptying. The inlet pipe 32 extends to the outer boundary of the exemplary module 1 and terminates there in an inlet flange 36. Similarly, the outlet pipe 34 extends to the system boundary of module 1 and terminates there in an outlet flange 38.Module 1 can be connected to an upstream module 120 via the inlet flange 36 and to a downstream module 130 via the outlet flange 38. Naturally, other process-related connection options are also possible, such as multiple inlets or outlets, or parallel connections of modules 1, 70, and 80.

[0034] Module 1 also includes a controller 20 for the local control of its process hardware 10. The controller 20 is configured to autonomously control the process hardware 10, for example, the electric motor 42 of the agitator 40 and the power electronics 52 of the heating element 50. This enables the controller 20 to bring Module 1 into a defined process state. Module 1 has a number of precisely defined process states and can autonomously switch between these states upon command. This allows the module, for example, to autonomously carry out a subprocess without external influence.

[0035] Module 1 can also include, for example, sensors such as flow, pressure, or temperature sensors, or electrically operated valves or similar elements (not shown). Such sensors or actuators are also connected to the controller 20 and can be queried or controlled by the controller 20.

[0036] The controller 20 has I / O modules 24 and 26 for this purpose, which it can use to control actuators such as the electric motor 42 of the agitator 40 or the power electronics 52 of the heating element 50. Additional I / O modules for sensors or other actuators are available if required for the process function of module 1.

[0037] Modules 70 and 80, and other modules, can be structured similarly to Module 1, also featuring a control system similar to Control System 20. This control system can locally and autonomously manage the process hardware of the respective module and bring the module into a number of specific, defined states. Accordingly, Modules 1, 70, and 80 are self-contained in terms of their control systems, so that the process hardware and control system together form a flexibly deployable module for a process plant 90. This module can be assembled into a complete plant 90 virtually via "plug and play," both in terms of process and control systems.

[0038] The entire system 90 comprises a higher-level control unit 60, which is connected to the individual modules 1, 70, and 80 via a bus 62. The higher-level control unit only needs to send precisely defined commands to the individual modules 1, 70, and 80 so that they assume one of their predetermined, defined states. The higher-level control unit 60 does not need to know the control details or the individual elements of the process hardware 10 of the respective modules 1, 70, and 80, nor does it need to control these individual elements. On the contrary, the higher-level control unit 60 should preferably only send "high-level" commands to the individual modules 1, 70, and 80, so that they can then autonomously assume the respective states to carry out their respective process steps. This control concept simplifies the planning, design, and construction of process systems 90.Module 1 essentially brings with it its complete control system in a modular manner, in addition to its process-related hardware 1, thus minimizing the overall control effort.

[0039] For communication between the controller 20 of module 1 and the higher-level controller 60 or the other modules 70, 80 via bus 62, the controller 20 has an external interface 22. Through the external interface 22, module 1 can receive a number of defined commands corresponding to specific defined states of its process hardware 10. Preferably, the external interface 22 can only receive commands corresponding to specific defined states of the process hardware 10. The controller 20 is then responsible for independently controlling the transition of the process hardware 10 between these specific defined states without external commands.

[0040] Furthermore, the controller 20 can independently handle all safety, signaling, and logging functions for the respective module 1, thus relieving the higher-level controller 60 of this task. It is also possible to operate module 1 manually via the controller 20 without a higher-level controller, for example, when only very small quantities are to be produced and integration into a higher-level controller would not be worthwhile. For this purpose, module 1 has its own user interface or control panel.

[0041] Module 1 can also issue defined commands to upstream, downstream, or parallel modules via external interface 22. For example, Module 1 can inform upstream Module 70 to forward a semi-finished product to Module 1 if Module 1 is to process it. Similarly, Module 1 can issue a defined command to downstream Module 80 when it has completed processing and wants to forward the finished intermediate product to Module 130 for further processing. Accordingly, Modules 1, 70, and 80 can implement horizontal communication with each other without necessarily requiring a higher-level controller 60.

[0042] Examples of defined states for modules 1, 70, and 80 are: "idle," "running," "halt," "stopped," "aborted," and "finished." Furthermore, the "running" state can be subdivided into different operating modes if this is possible for the subprocess. This allows the subprocess to run, for example, with different parameters or with different sequences. Accordingly, appropriately defined commands can be transmitted to module 1 via the external interface 22 to instruct its controller 20 to move to the corresponding state.

[0043] The transition between the individual states is then autonomously controlled by the controller 20. For example, if the product in reactor 30 is to be processed according to a specific temperature curve and at a specific speed of the stirrer 40, the controller 20 uses I / O modules 24 and 26 to adjust the rotational speed of the motor 42 of the stirrer 40 and the power supplied by the power unit 52 to the heating element 50 in order to heat the product in reactor 30 according to the temperature curve. As soon as the desired state of module 1 is reached, the external interface 22 can communicate this to the higher-level controller 60 or to upstream, downstream, or parallel-connected modules 70 and 80. Furthermore, status data from the module can also be output to the higher-level controller 60 via the external interface 22, for example, for visualization or statistical analysis.

[0044] Fig.Figure 2 shows a flowchart for a method for controlling a process plant 90, where the plant is composed of several modules 1, 70, 80, each containing process hardware for carrying out a subprocess. In step 100, a command from a number of defined commands for the respective module 1 is received via the external interface 22 of module 1. These commands correspond to a number of specific defined states of the process hardware of module 1.

[0045] After Module 1 receives the defined command for a state change, in step 110 it uses its internal controller 20 to control its process hardware in order to bring it into the desired defined state. Once this has occurred, in step 140 the module can issue defined commands to upstream, downstream, or parallel modules 70 and 80 to instruct them to carry out their respective subprocesses of the process. Furthermore, in step 150, Module 1 can output data to the higher-level controller 110, for example, to display the internal state of Module 1 or to signal the completion of an intermediate product.

[0046] Step 100, receiving a command from the set of defined commands for module 1 via the external interface of a module, can be performed in step 120 by one of the upstream, downstream, or parallel modules 70 or 80. In step 130, defined commands from module 1 can be received by a higher-level controller 60.

[0047] Furthermore, in step 150, the controller 20 also outputs a module-specific operating screen 28 to the higher-level controller 60. This preferably occurs during the initial commissioning of module 1. It transmits its operating screen 28 to the higher-level controller 60, which describes, among other things, the module's properties and control options. The higher-level controller then recognizes module 1 in terms of its data and integrates it as a pre-configured data module into its control software. The operating screen 28 includes, in particular, a description of the module's function, the defined states, the defined commands, and preferably a user interface and a graphical representation of the module. Reference symbol list: 1 module 10 process engineering hardware 20 Control 22 External interface 24.26 I / O module 28 Operating diagram 30 reactor 32 Admission line 34 Outlet pipe 36 Inlet flange 38 Outlet flange 40 agitator 42 Engine 50 heating element 52 Power Electronics 60 higher-level control 62 Data bus 70, 80 more modules 90 process engineering plant 100 Receiving an order 110 autonomous control of the process engineering hardware 120 Receiving a command from other modules 130 Receiving a command from a higher-level control system 140 Outputting commands to other modules 150 Outputting data or an operator interface to a higher-level control system

Claims

A process plant (90) comprising several modules (1, 70, 80) and a higher-level plant control system (60), each of the modules (1, 70, 80) comprising: a. process hardware (10) for carrying out a process subprocess; b. a controller (20) for local control of the process hardware (10), wherein the controller (20) is configured to autonomously control the process hardware (10) and bring it into a number of predetermined defined states; and wherein c. a defined command is assigned to bring it into one of the predetermined defined states; and wherein d. the controller (20) is configured to autonomously control a transition of the process hardware (10) between the predetermined defined states without external commands;unde. an external interface (22) of the controller (20), wherein the external interface (22) is configured to receive the defined commands corresponding to the predetermined defined states of the process hardware (10); wherein the external interface (22) is configured to communicate an operating screen (28) to the higher-level controller (60), wherein the operating screen (28) contains a description of the function of the module (1), the predetermined defined states and the defined commands, and wherein the operating screen (28) is designed such that the module (1) can be integrated into the software of the higher-level controller (60) as a pre-configured data module and is integrated into its control software by the higher-level controller as a pre-configured data module;and wherein the higher-level plant control (60) is designed to output defined commands that correspond to the specific defined states of the process hardware (10) of the modules (1, 70, 80). Process engineering plant according to claim 1, wherein the external interface (22) of the modules (1, 70, 80) is configured to communicate the achievement of the state to a higher-level control system (60) and / or upstream or downstream or parallel-connected modules (70, 80). Process engineering plant according to one of claims 1 or 2, wherein the defined commands are exclusively high-level commands. Process engineering plant according to one of claims 1 - 3, wherein the external interface (22) of the modules (1, 70, 80) can only receive commands that correspond to the certain defined states of the process engineering hardware (10). Process engineering plant according to one of claims 1 - 4, wherein no intermediate states of the process engineering hardware (10) can be controlled via the external interface (22) of the modules (1, 70, 80). Process engineering plant according to one of claims 1 - 5, wherein the external interface (22) of the modules (1, 70, 80) is further configured to output defined commands to upstream or downstream or parallel connected modules (70, 80). Process engineering plant according to one of claims 1 - 6, wherein the external interface (22) of the modules (1, 70, 80) is configured to receive the defined commands from upstream or downstream or parallel connected modules (70, 80). Process engineering plant according to one of claims 1 - 7, wherein the external interface (22) is further configured to receive the defined commands from the higher-level plant control (60). Process engineering plant according to one of claims 1 - 8, wherein the external interface (22) is further configured to output signals to the higher-level plant control (60). Method for controlling a process plant (90), wherein the plant (90) is composed of several modules (1, 70, 80) and a higher-level controller (60), wherein the modules (1, 70, 80) each have process hardware (10) for carrying out a process subprocess, as well as a controller (20) for local control of the process hardware (10) and an external interface (22) of the controller (20), wherein the external interface (20) receives defined commands corresponding to predetermined defined states of the process hardware (10), and the method comprises the following steps: a. Receiving (100) through the external interface (10) of a module (1, 70, 80) a defined command from the number of defined commands for the respective module (1, 70, 80); b.autonomous control (110) of a transition between the predetermined defined states of the process hardware (10) of a module (1, 70, 80) by the corresponding controller (20) according to the received defined command, in order to bring the process hardware (10) of the module (1, 70, 80) into a predetermined defined state; and c. communication via the external interface (22) of one of the modules (1, 70, 80), an operator panel (28) to the higher-level controller (60), wherein the operator panel (28) contains a description of the function of the module (1, 70, 80), the predetermined defined states and the defined commands, and wherein the operator panel (28) is designed such that the module (1) can be integrated into the software of the higher-level controller (60) as a pre-configured data module; and d. wherein the module (1) is integrated into the control software by the higher-level control system as a pre-built data module. The method according to claim 10, further comprising at least one of the following steps: - Receiving (120) by at least one of the modules (1, 70, 80) defined commands from upstream or downstream or parallel-connected modules (1, 70, 80); and / or - Receiving (130) by at least one of the modules (1, 70, 80) defined commands from the higher-level control (60). Method according to one of claims 10 or 11, further comprising at least one of the following steps: - Output (140) by at least one of the modules (1, 70, 80) of defined commands to upstream or downstream or parallel modules (1, 70, 80); and / or - Output (150) by at least one of the modules (1, 70, 80) of data to the higher-level controller (60). Method according to one of claims 10 - 12, further comprising the following step: - Communicating the achievement of the state of the modules (1, 70, 80) to the higher-level control (60) and / or to upstream or downstream or parallel-connected modules (70, 80) through the external interface (10) of the module (1, 70, 80).

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