Automated Availability Calculation from Reliability Block Diagrams
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Solution Overview
Problem
Current methods for determining the instantaneous availability of complex control systems in industrial plants are time-consuming and require significant human resources, making it difficult to continuously analyze and update reliability block diagrams, especially during operation.
Innovation Solution
An automated method that generates a reliability block diagram from a function plan, calculates the current availability of a technical system, and displays it in real-time, using a graph-based approach with a backward propagation method and transformation algorithms like ATL, allowing for dynamic and continuous availability calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual generation of reliability block diagram is used, then reliability analysis can be performed, but enormous amount of human resources and time are required
Solution Approach 1:
The patent replaces the manual mechanical process of creating reliability block diagrams with an automated computer-based system. The control system automatically generates the reliability block diagram from process control data and calculates availability without human intervention, substituting manual labor with automated computational processes.
Solution Approach 2:
The system performs self-service by automatically determining its own availability metrics. The control system queries the status of its own components, generates the reliability block diagram, and calculates availability independently without requiring external manual analysis, enabling continuous self-monitoring.
2Reliability
If manual generation of reliability block diagram is used, then reliability analysis can be performed, but continuous analysis during operation is not possible
Solution Approach 1:
The patent enables continuous availability determination during system operation. The control system continuously queries component statuses and recalculates availability in real-time, maintaining uninterrupted monitoring throughout the operational lifecycle rather than performing discrete periodic analyses.
Solution Approach 2:
The system performs preliminary actions by pre-establishing the reliability block diagram structure from process control data before operation begins. This allows the system to quickly calculate availability as components fail or are repaired without requiring time-consuming manual reconstruction of the reliability model.
3Adaptability or versatility
If design changes are reflected in reliability block diagram, then updated reliability analysis can be performed, but it is very time-consuming for complex systems
Solution Approach 1:
The patent creates a dynamic reliability block diagram that automatically adapts to design changes. When process control data changes due to design modifications, the system automatically updates the reliability block diagram structure and recalculates availability, transforming the static manual update process into a dynamic automated response.
4Reliability
If Monte Carlo simulation is used for availability calculation, then theoretical availability can be determined, but significant computing effort is required
Solution Approach 1:
The patent extracts the essential availability calculation from complex Monte Carlo simulations. Instead of performing extensive probabilistic simulations for each component, the system uses the reliability block diagram structure to directly calculate availability based on component statuses, removing the computationally intensive simulation layer while retaining the core availability assessment function.
Data Source
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AI summary
The invention relates to a method for operating an automated technical system comprising a plurality of hardware components that are interconnected according to a design plan to control a process within the system. The method according to the invention is designed such that, in a first step, a reliability block diagram for the system or parts thereof is automatically generated from the system's functional plan. Furthermore, status information is queried and/or read out for each component (optionally from the functional plan). Based on the reliability block diagram and the status information of each component, a graph is generated with which the current availability of the system or parts thereof is calculated.This information is displayed on a display unit, and the current availability can now be considered by an operator during the ongoing operation of the technical system to determine whether an intervention in the operation of the technical system is to be carried out.