Computer-implemented mobile orchestration instance and method for creating automation of a technical system

Abstract

The invention proposes a computer-implemented mobile orchestration instance (2) which is designed a) to define task types (3, 3a), wherein the task types (3, 3a) each comprise a sequence of work steps (5, 6) and associated parameters (4, 7, 8) which are necessary for a mobile device of a process system of a specific type to implement a specific transport operation and / or handling operation, b) to instantiate one or more of the task types (3, 3a) as an executable software instance (4, 7, 8) as part of the computer-implemented mobile orchestration instance (10) in order to define one or more task services (9, 9a), c) to encapsulate the task services (9, 9a) as services (10a, 10b, 10c, 10d, 10e, 10f) according to the standard VDI / VDE / NAMUR 2658 which is valid at the time of the present patent application, and d) to integrate the encapsulated task services (9, 9a) into a computer-implemented orchestration instance (1) using an OPC UA server (12) provided by the computer-implemented mobile orchestration instance (2).

Description

[0001] Description

[0002] Computer-implemented mobile orchestration instance and method for creating an automation of a technical plant

[0003] The invention relates to a method for creating an automation system for a production process of a process plant. The invention also relates to a computer-implemented mobile orchestration instance. Furthermore, the invention relates to a process plant with a computer-implemented orchestration instance. Finally, the invention relates to a control system for a process plant, comprising an operator station client and an operator station server for operating and monitoring the process plant.

[0004] Autonomous mobile robots (AMRs) are primarily used in manufacturing for a wide range of transport and handling tasks. However, it is becoming increasingly clear that AMRs can also offer significant added value in the process industry. Their use is particularly well-suited for repetitive or hazardous tasks (e.g., heavy lifting) that can be effectively handled by robotics and its automation. AMRs are also ideally suited for cleanroom applications, as they do not introduce contaminants such as hair or skin particles into the cleanroom environment, unlike humans.

[0005] In addition to these specific reasons for the use of mobile robotics, the general shortage of skilled workers also necessitates increasing automation of production processes in the process industry, which can be further advanced through the use of AMRs. Tasks such as container or reactor transport, automated sampling, or the reading of measured values ​​appear to be beneficial for future highly automated production processes in the process industry.

[0006] One challenge in the current use of mobile robotics is the integration of AMR (Automated Manual Robotics) into the relevant control systems of process plants. These process control systems are now designed so that production recipes can be created within them and executed by the connected equipment.

[0007] For the future use of mobile robotics in process plants, the transport and handling functionalities provided by the AMR must be able to be integrated into recipe creation and execution in a similar way to today's production functions.

[0008] Furthermore, particularly in the context of modular, highly flexible, and adaptable production systems, there is a requirement to integrate the equipment needed for production (including mobile robotics in the future) into the production system automatically, and therefore quickly and easily. This minimizes the engineering effort required for the production systems. Automating this integration, however, necessitates standardizing the automation interfaces of the equipment.

[0009] From the perspective of mobile robotics, this presents two challenges that need to be addressed:

[0010] • A way must be provided to integrate transport and handling operations into process control systems, in addition to production operations.

[0011] • The aim is to enable largely automated integration of mobile robotics based on standardized interfaces.

[0012] The invention is based on the objective of making the integration of a mobile device with transport and / or handling operations into the orchestration of a process plant with production operations simple, efficient and automated.

[0013] This problem is solved by a method for creating an automation system for a production process of a process plant according to claim 1. Furthermore, the problem is solved by a computer-implemented mobile orchestration instance according to claim 12. The invention also relates to a process plant with a computer-implemented orchestration instance and a control system for a process plant. Advantageous embodiments are the subject of the dependent claims.

[0014] A method according to the invention for creating automation for a production process of a process plant, wherein the production process comprises at least one production operation and at least one transport operation and / or one handling operation, and wherein the process plant has at least one process module for carrying out the production operation and at least one mobile device of a specific type for carrying out the transport operation and / or the handling operation, comprises the following steps: a) Defining task types by a computer-implemented mobile orchestration instance, wherein the task types each comprise a sequence of work steps and associated parameters that are necessary for a mobile device of a specific type to perform a specific transport operation and / or handling operation.b) Instantiating one or more of the task types as an executable software instance as part of the mobile orchestration instance to define one or more task services, c) Encapsulating the task services as services in accordance with the VDI / VDE / NAMUR 2658 standard, which is valid at the time of the present patent application, by the computer-implemented mobile orchestration instance, d) Integrating the encapsulated task services into a computer-implemented orchestration instance using an interface provided by the computer-implemented mobile orchestration instance, in particular an OPC UA server, e) Creating the automation for the production process incorporating the integrated, encapsulated task services by the computer-implemented orchestration instance.

[0015] Automation encompasses various process steps such as switching devices on and off, controlling process parameters like temperature, pressure, or flow rate, monitoring sensor data, and acquiring operational data from the process plant. Automation includes at least the parameterization of the plant components and the interaction of these components with one another.

[0016] A production process refers to a series of steps or activities carried out to transform raw materials or components into a finished product within the processing plant. The production process can include various phases, such as design, raw material procurement, manufacturing, assembly, and packaging.

[0017] A process plant is a technical facility used in the process industry, such as a chemical, pharmaceutical, petrochemical, or food and beverage plant. A production operation is a single step or activity within the production process of the process plant, in which raw materials or components are transformed into an intermediate or finished product. A production operation can include various tasks, such as stirring, heating, mixing, centrifuging, or sieving.

[0018] A transport operation refers to the process of physically moving goods or materials from one place to another. It encompasses the movement of goods along a specific route – by land, water, or air.

[0019] Handling operations can include lifting, carrying, moving, stacking, or packaging materials. This can be done using mobile equipment such as forklifts, cranes, or conveyor belts, as well as mobile robots.

[0020] The process plant comprises at least one process module, such as a mixer, agitator, or heater, designed to perform the production operation(s). Furthermore, the process plant includes a mobile device of a specific type, such as a robot with a gripper arm and a drive, designed to perform the transport or handling operations.

[0021] The method according to the invention follows a particularly advantageous type-instance concept. First, task types are defined by a computer-implemented orchestration instance, each task type comprising a sequence of work steps and associated parameters. These are necessary so that a mobile device of the specific type (e.g., the type "robot with gripper arm and drive") can perform certain transport and / or handling operations. An example of a task type could be "taking a sample".The mobile orchestration instance specifies parameters such as the node to be visited where a sample is to be collected (#SampleNode), the quantity to be dispensed (#SampleQuantity), and the ID of the device type to be used (#RobotType). It also defines the necessary steps for the task type, such as "selection of a suitable mobile device," "control of the corresponding mobile device according to the operating scenario," and, if required, "interaction with external systems," such as an AI system for image recognition. In a second step, one or more of these task types are instantiated as an executable software instance as part of the computer-implemented mobile orchestration instance. This defines one or more task services.

[0022] The task services are encapsulated (externally) as services according to the VDI / VDE / NAMUR 2658 standard, which was valid at the time of this patent application, by the computer-implemented mobile orchestration instance. This encapsulation means that the mobile orchestration instance provides an MTP-based interface (MTP = Module Type Package) for the task services. Furthermore, each encapsulated task service includes a ServiceControl interface according to the VDI / VDE / NAMUR 2658 standard to enable its state-based control.

[0023] The invention enables functional encapsulation for systems coordinating mobile devices, particularly mobile robotics. Their functionality can be made available to a processor orchestration system, the orchestration instance, particularly easily and efficiently via a standardized, MTP-based interface. This facilitates, in particular, the automated integration of mobile robotics into modular production systems. The standardization of the interfaces reduces the previously necessary coordination efforts to a minimum.

[0024] The disclosed solution also allows for any configuration of task types for controlling the mobile device, especially mobile robotics. Thus, depending on the operating scenario, any mobile device can be used and any transport and handling operations can be implemented.

[0025] The solution thus combines the goals of adaptability (through the advantageous use of the mobile orchestration instance) and easy integration (through the use of MTP-based, standardized interfaces). Furthermore, it offers the possibility of connecting external AI applications.

[0026] An OPC UA server is typically used as the interface to the orchestration instance. However, an interface based on MQTT or REST can also be provided. Preferably, the computer-implemented mobile orchestration instance provides a single OPC UA server for all task services. Alternatively, the computer-implemented orchestration instance can provide a separate OPC UA server for each task service.

[0027] Preferably, prior to integrating the task services into the computer-implemented orchestration instance, an MTP file for each task service is generated by the computer-implemented mobile orchestration instance in accordance with the VDI / VDE / NAMUR 2658 standard, which is valid at the time of the present patent application, and made available to the computer-implemented orchestration instance. The MTP file describes precisely that one task service. An MTP file is generated for each task service, integrated into the orchestration instance, and managed by it.

[0028] Alternatively, prior to integrating the task services into the computer-implemented orchestration instance, a single MTP file for all task services can be generated by the computer-implemented mobile orchestration instance and made available to the computer-implemented orchestration instance, in accordance with the VDI / VDE / NAMUR 2658 standard, which was valid at the time of the present patent application. With this embodiment of the method, therefore, only a single MTP file for all task services needs to be generated, integrated into the orchestration instance, and managed there.

[0029] Alternatively, prior to integrating the task services into the computer-implemented orchestration instance, a single MTP file can be generated by the computer-implemented mobile orchestration instance for all task types, in accordance with the VDI / VDE / NAMUR 2658 standard valid at the time of this patent application. This file can then be integrated into the orchestration instance and managed there. A kind of meta-MTP file is created, which defines each task type and previously defined placeholders. Depending on the number of task services (instances of the task types), these placeholders later become concrete MTP instances.

[0030] The production process can comprise a multitude of individual process steps with production operations, transport operations, and handling operations. Automation is generated for these steps by the computer-implemented orchestration instance, whereby each process step associated with a transport or handling operation is assigned an encapsulated task service. Information about all available task services is available to the orchestration instance through the prior integration of the MTP files. The assignment of task services specifies which operation is to be implemented in a process step.

[0031] For each assigned, encapsulated task service, the computer-implemented mobile orchestration instance can also define associated procedure and configuration parameters. These procedure or configuration parameters might include, for example, waypoints designated for a system or a selection of the gripper type to be used. For the "Sample Taking" task service, one procedure parameter would be the point at which the sample is to be taken. Other procedure parameters might include the quantity to be taken or the location where the sample is to be taken.

[0032] As part of a preferred training program, the production process runs using the previously created automation, employing the process module and the mobile device. In other words, the created automation is used as intended to automate the production process.

[0033] For communication with the mobile orchestration instance, the computer-implemented orchestration instance can provide an OPC UA client.

[0034] Preferably, the computer-implemented mobile orchestration instance transmits the current operating mode of an encapsulated task service to the computer-implemented orchestration instance during the production process. The standard VDI / VDE / NAMUR 2658 offers the possibility of defining different procedures, i.e., different operating modes, within a single service. This operating mode principle can be used within the framework of a method according to the invention to transmit information about the state of a work step to the orchestration instance at relevant points. This is advantageous in most cases when a transport and / or handling operation runs parallel to a production operation and must be synchronized with it.

[0035] The previously formulated task is further solved by a computer-implemented mobile orchestration instance which is configured to: a) define task types, each task type comprising a sequence of work steps and associated parameters necessary for a mobile device of a process plant of a specific type to perform a specific transport and / or handling operation; b) instantiate one or more of the task types as an executable software instance as part of the mobile orchestration instance in order to define one or more task services; c) encapsulate the task services as services in accordance with the VDI / VDE / NAMUR 2658 standard, which is valid at the time of the present patent application; and d) integrate the encapsulated task services into a computer-implemented orchestration instance using an OPC UA server provided by the computer-implemented mobile orchestration instance.

[0036] Preferably, the computer-implemented mobile orchestration instance is designed to transmit an up-to-date operating mode of an encapsulated task service to the computer-implemented orchestration instance during the production process.

[0037] The previously formulated task is also solved by a process plant comprising a computer-implemented orchestration instance, a computer-implemented mobile orchestration instance, a process module and a mobile device, wherein the process plant is configured to perform a procedure as previously explained.

[0038] The previously formulated task is also solved by a control system for a process plant, which has an operator station client and an operator station server for operating and monitoring the process plant, wherein the orchestration instance and / or the mobile orchestration instance are computer-implemented on the operator station server as previously explained.

[0039] In this context, an "Operator Station Server" is understood to be a server that centrally collects data from an operator control and monitoring system, as well as typically alarm and measurement archives from the process plant's control system, and makes this data available to users. The Operator Station Server usually establishes a communication link to the process plant's automation systems and forwards process plant data to so-called clients, which are used to operate and monitor the individual functional elements of the process plant. The Operator Station Server can have client functions to access the data (archives, messages, tags, variables) of other Operator Station Servers. This allows for the combination of process plant operating data on the Operator Station Server with variables from other Operator Station Servers (server-to-server communication).The Operator Station Server can be, but is not limited to, a SIMATIC PCS 7 Industrial Workstation Server from SIEMENS.

[0040] The properties, features, and advantages of this invention described above, as well as the manner in which they are achieved, will become clearer and more readily understandable in connection with the following description of exemplary embodiments, which are explained in more detail in conjunction with the drawings. The drawings show:

[0041] FIG 1 shows a schematic representation of a method according to the invention; and

[0042] FIG 2 shows a flowchart of a production process.

[0043] Figure 1 schematically depicts an orchestration instance 1 and a mobile orchestration instance 2, which are computer-implemented on an operator station server of a process plant's control system. The two instances 1 and 2 can also be implemented on separate computers. The only requirement is that a communication link exists between the two instances 1 and 2.

[0044] The process plant comprises at least one process module and a mobile device, which is designed as a robot with a gripper arm and a drive. A production process is to be carried out automatically within the process plant. This requires automation that includes parameters for controlling, operating, and monitoring the production process.

[0045] The following describes the creation of such automation using a method according to the invention. In a first step (1), the computer-implemented mobile orchestration instance defines two task types 3 and 3a. Each task type 3 comprises a sequence of work steps and associated parameters necessary for a robot of a specific type to perform a particular transport and / or handling operation. For example, for the task type "Take sample" 3, the work steps "Select robot" 5 and "Move to node XY" 6, as well as the parameters "Sample node" 4, "Sample quantity" 7, and "Robot type" 8, are defined.

[0046] In a second step (2), task types 3 and 3a are instantiated as executable software instances as part of the mobile orchestration instance 2, thereby defining several task services 9 and 9a. Task services 9 and 9a are thus characterized by the fact that they comprise a software engine with which the work steps of the respective task type 3 and 3a, from which the task services 9 and 9a were created, can be executed.

[0047] Task services 9 and 9a are encapsulated by the mobile orchestration instance 2 as services 10a, 10b, 10c, 10d, 10e, and 10f according to the VDI / VDE / NAMUR 2658 standard, which was valid at the time of the present patent application. A single MTP file 11 is generated for all task services 9 and 9a, encompassing services 10a, 10b, 10c, 10d, 10e, and 10f. The mobile orchestration instance 2 implements an OPC UA server 12, which is communicatively connected to the orchestration instance 1. In a third step (3), the MTP file is made available to the orchestration instance 1 from this OPC UA server 12.

[0048] In a fourth step (4), orchestration instance 1 specifies a production recipe 13 for the production process. This recipe comprises individual process steps 14a, 14b, 14c, which include production operations, transport operations, and / or handling operations such as "container transport," "reaction," or "sample draw." A task service 9, 9a from orchestration instance 2 is assigned to each process step 14a, 14b, 14c that is associated with a transport and / or handling operation. The assignment of task services 9, 9a specifies which robot operation is to be performed in a process step 14a, 14b, 14c. Furthermore, if a task service 9, 9a is assigned to a process step 14a, 14b, 14c, values ​​must be specified for all defined procedure and configuration parameters 15 of the respective task service 9, 9a.

[0049] The automation is then fully created and production recipe 13 can be executed. In a fifth step (5), orchestration instance 1 implements an OPC UA client 16. This client allows orchestration instance 1 to read and write to the MTP-based services 12a, 12b, 12c, 12d, 12e, and 12f provided by orchestration instance 2 in the OPC UA server 2. In this way, orchestration instance 1 can transmit the parameter values ​​15 defined in production recipe 13 to the task services 9 and 9a of mobile orchestration instance 2 and perform state-based control of these task services according to production recipe 13.

[0050] The use of the MTP concept offers the advantageous possibility of defining different procedures, i.e., different modes of operation, within a single service 12a, 12b, 12c, 12d, 12e, 12f. This principle can be used to transmit information about the state of a task type 3, 3a to the orchestration instance 1 at relevant points. This is necessary in most cases when a transport and / or handling operation runs in parallel with a production operation and needs to be synchronized with it.

[0051] Figure 3 illustrates the use of different driving modes within task services 9 and 9a using the example service "Sample Taking". The sample taking functionality itself is implemented in the process module, while the necessary transport and handling of the bottle are carried out by the mobile device, i.e., the robot, which is coordinated by the computer-implemented mobile orchestration instance 2.

[0052] First, the computer-implemented orchestration instance 1 starts the sampling service with driving mode 1, whereupon the mobile device moves to the process module from which a sample is to be taken. There it positions the bottle.

[0053] By restarting the sampling service into operating mode 2, the computer-implemented mobile orchestration instance 2 signals to the computer-implemented orchestration instance 1 that the bottle is positioned. The computer-implemented orchestration instance 1 then starts the sampling operation of the process module.

[0054] Once the sampling process is complete, the computer-implemented mobile orchestration instance 2 restarts the sampling service into operating mode 3, signaling to the computer-implemented orchestration instance 1 that the process module can resume its function. The mobile device then seals the sample, is coordinated to a delivery point, and delivers the filled sample. In this way, switching operating modes at relevant points in the process allows for synchronization between the processes in the computer-implemented mobile orchestration instance 2 and the process modules involved.

[0055] Although the invention has been illustrated and described in detail by the preferred embodiment, the invention is not limited by the disclosed examples and other variations can be derived from them by a person skilled in the art without leaving the scope of protection of the invention.

Claims

Patent claims 1. A method for creating automation for a production process of a process plant, wherein the production process comprises at least one production operation and at least one transport operation and / or one handling operation, and wherein the process plant has at least one process module for carrying out the production operation and at least one mobile device of a certain type for carrying out the transport operation and / or the handling operation, the method comprising: a) defining task types (3, 3a) by a computer-implemented mobile orchestration instance (2), wherein the task types (3, 3a) each comprise a sequence of work steps (5, 6) and associated parameters (4, 7, 8) that are necessary for a mobile device of the certain type to perform a certain transport operation and / or handling operation, b) instantiating one or more of the task types (3,3a) as an executable software instance as part of the mobile orchestration instance (2) to specify one or more task services (9, 9a), c) encapsulations of the task services (9, 9a) as services (10a, 10b, 10c, 10d, 10e, 10f) in accordance with the standard VDI / VDE / NAMUR 2658, which is valid at the time of the present patent application, by the computer-implemented mobile orchestration instance (2), d) integration of the encapsulated task services (9, 9a) into a computer-implemented orchestration instance (1) using an interface (12) provided by the computer-implemented mobile orchestration instance (2), in particular an OPC UA server, e) creation of the automation for the production process by incorporating the integrated, encapsulated task services (9, 9a) by the computer-implemented orchestration instance (1).

2. Method according to claim 1, wherein the computer-implemented mobile orchestration instance (2) provides a single OPC UA server (12) for all task services )9, 9a).

3. Method according to claim 1, wherein the computer-implemented mobile orchestration instance (2) provides a separate OPC UA server (12) for each task service (9, 9a).

4. Method according to one of the preceding claims, wherein, prior to the integration of the task services (9, 9a) into the computer-implemented orchestration instance (1), an MTP file (11) in accordance with the standard VDI / VDE / NAMUR 2658, which is valid at the time of the present patent application, is generated by the computer-implemented mobile orchestration instance (2) for each task service (9, 9a) and made available to the computer-implemented orchestration instance (1).

5. Method according to one of claims 1 to 3, wherein, prior to the integration of the task services (9, 9a) into the computer-implemented orchestration instance (1), a single MTP file (11) in accordance with the standard VDI / VDE / NAMUR 2658, which is valid at the time of the present patent application, is generated by the computer-implemented mobile orchestration instance (2) and made available to the computer-implemented orchestration instance (1) for all task services (9, 9a).

6. Method according to one of claims 1 to 3, wherein, prior to the integration of the task services (9, 9a) into the computer-implemented orchestration instance (1), a single MTP file (11) in accordance with the standard VDI / VDE / NAMUR 2658, which is valid at the time of the present patent application, is generated by the computer-implemented mobile orchestration instance (2) and made available to the computer-implemented orchestration instance (1) for all task types (3, 3a).

7. Method according to any of the preceding claims, wherein the production process comprises a plurality of individual process steps with production operations, transport operations and handling operations, for which automation is generated by the computer-implemented orchestration instance (1), wherein each process step (14a, 14b, 14c) associated with a transport operation or a handling operation is assigned an encapsulated task service (9, 9a).

8. Method according to claim 7, wherein for each assigned encapsulated task service (9, 9a) associated procedure and configuration parameters (15) are also determined by the computer-implemented orchestration instance (1).

9. Method according to one of the preceding claims, wherein the production process is carried out using the previously generated automation, the process module and the mobile device are used.

10. The method of claim 9, wherein the computer-implemented orchestration instance (1) provides an OPC UA client (16).

11. Method according to one of the preceding claims, wherein the computer-implemented mobile orchestration instance (2) transmits an up-to-date driving mode of an encapsulated task service (9, 9a) to the computer-implemented orchestration instance (1) during the course of the production process.

12. Computer-implemented mobile orchestration instance (2) configured to define task types (3, 3a), wherein the task types (3, 3a) each comprise a sequence of work steps (5, 6) and associated parameters (4, 7, 8) necessary for a mobile device of a process plant of a specific type to perform a specific transport and / or handling operation; b) instantiating one or more of the task types (3, 3a) as an executable software instance as part of the computer-implemented mobile orchestration instance (2) to define one or more task services (9, 9a); c) encapsulating the task services (9, 9a) as services (10a, 10b, 10c, 10d, 10e, 10f) in accordance with the VDI / VDE / NAMUR 2658 standard valid at the time of the present patent application; and d) the encapsulated task services (9,9a) to integrate into a computer-implemented orchestration instance (1) using an OPC UA server (12) provided by the computer-implemented mobile orchestration instance (2).

13. Computer-implemented mobile orchestration instance (2) according to claim 12, which is configured to transmit an actual driving mode of an encapsulated task service (9, 9a) to the computer-implemented orchestration instance (1) during the course of the production process.

14. Process plant comprising a computer-implemented orchestration instance (1), a computer-implemented mobile orchestration instance (2), a process module and a mobile device, which is configured to perform a method according to any one of claims 1 to 12.

15. Control system for a process plant comprising an operator station client and an operator station server for operating and monitoring the process plant, wherein the orchestration instance (1) and / or the mobile orchestration instance (2) according to one of claims 1 to 12 are computer-implemented on the operator station server.

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