Autonomous Process Modules With Service Interfaces for Flexible Output
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Solution Overview
Problem
Conventional production systems in the process industry, such as chemical and pharmaceutical sectors, face challenges in handling fluctuating product quantities due to their design for specific production rates, requiring complex reconfiguration and inefficient batch operations, especially with insufficient documentation and outdated control hardware.
Innovation Solution
A modular technical system where each module has autonomous local control and an external interface for service publication and request, enabling independent communication and service orchestration between modules, allowing for flexible and efficient process engineering without a higher-level control entity, using an administration shell and OPC UA server for standardized information exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production systems are designed for specific production rates, then they can operate effectively at that rate, but they cannot handle fluctuating product quantities efficiently
Solution Approach 1:
The production system is divided into independent modular units, each capable of autonomous operation. These modules can be dynamically configured and reconfigured to adapt to varying production demands, allowing the system to handle fluctuating product quantities efficiently while maintaining high productivity at each module level.
Solution Approach 2:
The system employs dynamic module configuration where production modules can be automatically activated, deactivated, or reconfigured based on real-time production requirements. This dynamic adaptability allows the system to optimize productivity for different production rates without requiring complete system reconfiguration.
2Productivity
If system expansion or upgrade is performed, then production capacity can be increased, but complex reconfiguration and reprogramming of control systems is required
Solution Approach 1:
Each production module possesses autonomous control capabilities and can independently manage its own operations. When modules are added or upgraded, they self-integrate into the production system through standardized interfaces, eliminating the need for complex centralized reconfiguration and reprogramming of control systems.
Solution Approach 2:
The system uses universal standardized interfaces and communication protocols that allow different module types to work together seamlessly. This universality enables easy system expansion and upgrades without requiring custom control reconfiguration, as each module can interact with any other module through the standardized interface.
3Adaptability or versatility
If batch production systems are used to handle fluctuating quantities, then flexibility is improved, but unproductive time for cleaning and changeover increases
Solution Approach 1:
The modular production system enables continuous operation by allowing different modules to work in parallel on different products or processes. When one module needs cleaning or changeover, other modules can continue production, eliminating idle time and maintaining continuous useful action throughout the system.
Solution Approach 2:
Modules can be pre-configured with different production settings and tools before being deployed. This preliminary preparation allows for rapid changeover between different products or processes, minimizing the time required for cleaning and reconfiguration while maintaining the flexibility to handle fluctuating production quantities.
Data Source
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AI summary
The invention relates to a module (1) for a technical installation (90) having technical hardware (10) for carrying out a technical sub-process, a control (20) for local control of the technical hardware (10), wherein the control (20) is designed to autonomously control the technical hardware (10), and an outside interface (22) of the control (20), wherein the outside interface (22) has a management shell (23), wherein the management shell (23) publishes at least one service in relation to an output product (140) of the module (1) via a network (62), and wherein the outside interface (22) is designed to query at least one service based on an input product (130) of the module (1) via the network (62). The invention further relates to a corresponding system for carrying out a process by means of a technical installation (90) and to a corresponding method for carrying out a technical process by means of a technical installation (90).