Automation Device Online Sequence Control Modification
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Solution Overview
Problem
Current automation devices do not allow for real-time modification of sequence controls during the RUN mode, requiring changes to be made in an engineering system, recompiled, and loaded, which is inefficient and limits operator flexibility.
Innovation Solution
An automation device with an integrated operator system that includes an interpreter for processing sequence controls and an executable SFC editor, enabling online modifications and optimizations without recompilation, allowing interaction and linkage via process values and control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sequence controls are modified during RUN mode, then operator flexibility and process optimization time are improved, but system complexity and safety risks increase
Solution Approach 1:
The system separates the sequence control modification functionality into distinct components: the operator system handles runtime parameter changes and object activation, while the engineering system manages compilation and loading. This segmentation allows operators to flexibly modify sequence controls during RUN mode without increasing overall system complexity, as each subsystem maintains its specific responsibilities.
Solution Approach 2:
The patent introduces an intermediary mechanism (the runtime interpreter and object activation system) that mediates between operator inputs and the underlying automation device. This intermediary layer enables safe online modifications by translating operator actions into controlled system changes, preventing direct access to complex system internals and thus managing complexity while improving ease of operation.
2Loss of time
If sequence controls are modified during RUN mode, then project planning and optimization time are reduced, but reliability and system stability may be compromised
Solution Approach 1:
The system performs preliminary validation and compilation checks before applying runtime modifications. The engineering system compiles and validates sequence control changes before they are loaded into the automation device, ensuring that only reliable configurations are activated during RUN mode. This preliminary action prevents unstable modifications while enabling fast optimization cycles.
Solution Approach 2:
The operator system provides continuous feedback mechanisms that monitor system state during runtime modifications. When sequence controls are modified online, the system tracks changes, validates their impact on current process state, and provides feedback to operators about potential stability implications. This feedback loop maintains reliability by preventing modifications that would compromise system stability while allowing beneficial changes.
3Adaptability or versatility
If online modifications are enabled, then adaptability to changing process requirements is improved, but the risk of configuration errors increases
Solution Approach 1:
The system implements self-service mechanisms through automated validation, compilation checking, and error detection during online modifications. The runtime interpreter automatically validates modified sequence controls against system constraints and detects potential configuration errors before they affect process operation. This self-service approach enables high adaptability while minimizing configuration errors through automated quality control.
Solution Approach 2:
The patent applies preliminary anti-action by implementing preventive measures against configuration errors before they can harm the system. The engineering system performs compilation and validation checks that anticipate and prevent erroneous configurations from being loaded. During runtime, the operator system validates modifications before activation, preventing harmful configuration errors while maintaining process adaptability.
Data Source
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AI summary
The invention relates to an automation device 21 comprising at least one automation device 9 and an operator system 22 for visualizing and operating sequence control sequences (SFCs). During RUN operation of the automation device 9, objects 24 generated from the sequence sequences 16 are processed. These objects 24 parameterize and activate CFC functions 15, which are loaded into the automation device 9 and created using a Continuous Function Chart editor. Interaction and linking between the objects 24 and the CFC functions 15 are accomplished via process values 18 and control signals 19. Measures are proposed to enable modification of the sequence control during RUN operation of the automation device 9.In particular, the automation device 21 includes an operator system 22 whose OS server 23 is equipped with an interpreter for interpreting and processing the sequence control and for controlling the CFC functions 15 in the automation device 9, as well as an engineering interface for creating the step sequence using an SFC editor that runs on an OS client 25 of the operator system 22, and an interface for visualizing and operating the step sequence 16 during process control. Due to the interpretive processing of SFC* objects in the OS server 23, testing (debugging and optimization) is possible directly during process control, without the need for compilation and download to the automation device in a separate engineering system.