Hierarchical Batch Process Control via Parameter Expression Evaluation
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Solution Overview
Problem
Current control systems for batch production processes require significant storage and network bandwidth to manage interdependencies, which can lead to inefficiencies and increased costs in industrial automation.
Innovation Solution
The implementation of input and output parameter expressions within a hierarchical control system allows for the evaluation and transfer of data between supervisory and equipment control systems, reducing the need for storage and bandwidth by enabling more efficient data management and calculation within the supervisory layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional control systems are used to manage interdependencies in batch processes, then complete data management is achieved, but storage requirements and network bandwidth consumption increase significantly
Solution Approach 1:
The patent segments the control system into hierarchical levels (supervisory control and equipment control), with each level handling specific data processing tasks. The supervisory control system evaluates parameter expressions and determines values, while the equipment control system executes specific control functions. This segmentation allows data to be processed and filtered at appropriate levels, reducing the need to store and transmit all raw data across the entire system.
Solution Approach 2:
The patent implements preliminary action by evaluating parameter expressions and determining values in the supervisory control system before transmitting data to the equipment control system. This pre-processing of data at the supervisory level reduces the data volume that needs to be stored and transmitted to lower levels, thereby reducing storage requirements and network bandwidth consumption while maintaining complete data management.
2Reliability
If traditional control systems are used to manage interdependencies in batch processes, then complete data management is achieved, but network bandwidth consumption increases significantly
Solution Approach 1:
The hierarchical segmentation of the control system divides network traffic into different levels. The supervisory control system handles high-level parameter evaluation and value determination, while the equipment control system handles specific control commands. This segmentation reduces the overall network bandwidth consumption by eliminating redundant data transmission across the entire network.
Solution Approach 2:
By performing preliminary evaluation of parameter expressions and determination of values in the supervisory control system before data transmission, the patent reduces the volume of data that needs to be transmitted over the network. This pre-processing minimizes network bandwidth consumption while ensuring that complete and accurate data management is maintained throughout the system.
3Productivity
If data is transferred between supervisory and equipment control systems, then equipment control performance is improved, but data handling complexity increases
Solution Approach 1:
The patent segments data handling responsibilities across hierarchical levels. The supervisory control system handles parameter expression evaluation and value determination, while the equipment control system focuses on executing specific control functions. This segmentation improves equipment control performance by providing processed data at the appropriate level, while the standardized interface between levels reduces the overall data handling complexity.
Solution Approach 2:
The patent introduces an intermediary mechanism in the form of parameter expressions and value determination at the supervisory control level. This intermediary layer processes and prepares data before transmission to the equipment control system, improving equipment control performance while reducing complexity at the equipment level by providing pre-processed, ready-to-use data.
Data Source
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AI summary
According to various embodiments, an interdependency modeling method for controlling a batch process with an industrial automation system includes evaluating an input parameter expression residing in a level of a supervisory system of the industrial automation system to determine a value, transferring the value of the input parameter expression to a level of an equipment control system of the industrial automation system, transferring data from the level of the equipment control system to the level of the supervisory system, and evaluating an output parameter expression residing in the level of the supervisory system based on the data from the level of the equipment control system.