Adaptive Cross Plant Control System via OPC-UA Intermediary
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Solution Overview
Problem
Current industrial process control systems are inflexible and manufacturer-specific, requiring costly rebuilds for changes and relying on proprietary architectures, which limits adaptability and increases maintenance needs, while also being difficult for non-experts to operate due to complex programming languages and hardware dependencies.
Innovation Solution
A platform-independent adaptive process control system using OPC-UA architecture, which includes a plant process engine with a library of selectable command records, object linking and embedding for process control, and a unified programming interface, allowing for flexible integration with various PLCs and human machine interfaces, enabling remote steering and adaptation of industrial processes without on-site intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manufacturer-specific proprietary architectures are used, then system reliability is improved, but adaptability deteriorates and maintenance costs increase
Solution Approach 1:
The patent implements a universal control architecture that can interface with multiple different PLC manufacturers and control systems through standardized protocols. The system uses a common communication layer that supports various proprietary protocols, allowing one control system to work with multiple hardware platforms without requiring manufacturer-specific customizations, thereby achieving both reliability through proven PLC technology and adaptability through protocol versatility.
Solution Approach 2:
The patent introduces an intermediary communication layer between the supervisory control system and the PLC layer. This intermediary layer translates between proprietary PLC protocols and standardized communication interfaces, acting as a mediator that allows the upper-level control system to adapt to different manufacturers while maintaining reliable communication through established protocols.
2Reliability
If proprietary architectures are used, then system reliability is improved, but maintenance costs increase
Solution Approach 1:
The universal control architecture allows maintenance personnel to work with a single standardized system interface regardless of which PLC manufacturer is used. This reduces maintenance costs by eliminating the need for specialized knowledge of multiple proprietary systems while maintaining reliability through continued use of proven PLC hardware and communication protocols.
3Manufacturing precision
If complex programming languages are used, then control precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent segments the control system into distinct layers: the PLC layer handles complex control logic and precision operations using specialized programming languages, while the supervisory control layer uses simplified standardized interfaces for operational control. This segmentation allows complex precision control to be maintained in the PLC layer while the user interface remains simple and accessible to non-experts.
4Reliability
If manufacturer-specific systems are used, then system reliability is improved, but device complexity increases
Solution Approach 1:
The intermediary communication layer reduces overall system complexity by providing a standardized interface that abstracts away the complexities of different proprietary PLC systems. Instead of integrating multiple complex manufacturer-specific interfaces directly into the supervisory system, the intermediary layer handles protocol translation and communication management, simplifying the overall architecture while maintaining reliable connections to various PLC manufacturers.
Data Source
AI summary
An adaptive process control system and corresponding method for independent steering of plant control systems is provided, wherein a plant associated with the plant control system includes a plurality of interlocked elements of one or more operational unit of the plant. The operation of an operational unit is controlled by the plant control system by means of the elements interlocked to the plant control system, wherein the adaptive, independent process control system is accessible by a plant process engine including a plant controller unit connected via the supervisory control and data acquisition unit with at least one programmable logic controller of the plant control system. The operation of the plant and the operational units is controlled by means of the programmable logic controller and the plurality of interlocked elements.