Cellular Manufacturing Control with Dynamic Device Allocation
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Solution Overview
Problem
Current industry standards, such as IEC 61131-3 and IEC 61499, do not provide a reference architecture for achieving the system performance requirements needed to implement the concepts of Industry 4.0, specifically in terms of controlling and managing industrial devices in a flexible and agile manner.
Innovation Solution
A system comprising an access node and a computer system with processing circuitry to define and control manufacturing processes, allocate industrial devices, and implement controllers to perform these processes cooperatively, utilizing a cellular communications network for wireless signal transmission and reception.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional IEC standards (IEC 61131-3, IEC 61499) are used for controlling industrial systems, then functional blocks for automated control are provided, but system performance requirements for Industry 4.0 cannot be met
Solution Approach 1:
The patent implements dynamic allocation of industrial devices to manufacturing process instances, allowing the system to adapt flexibly to changing production requirements. The controller dynamically assigns and reassigns devices based on real-time needs, enabling both high reliability through standardized control and adaptability through flexible resource allocation.
Solution Approach 2:
The patent segments the manufacturing system into discrete manufacturing process instances (MPIs) that can be independently controlled and managed. Each MPI can be allocated specific industrial devices, allowing granular control while maintaining overall system performance requirements through standardized interfaces.
2Productivity
If manual control of industrial processes is used, then system stability is maintained, but productivity and automation level are reduced
Solution Approach 1:
The controller automatically performs device allocation, process instance management, and coordination without requiring manual intervention. The system self-manages the complexity of controlling multiple industrial devices by implementing automated allocation algorithms and standardized control procedures.
Solution Approach 2:
The patent introduces a controller as an intermediary between the manufacturing process instances and the industrial devices. This intermediary manages the complexity by providing standardized interfaces and automated control logic, enabling high productivity without requiring direct complex interactions between all system components.
3Adaptability or versatility
If industrial devices are statically assigned to manufacturing processes, then system stability is ensured, but adaptability to changing production requirements is reduced
Solution Approach 1:
The patent implements dynamic allocation where industrial devices can be reassigned to different manufacturing process instances based on real-time production requirements. This dynamic approach enables rapid reconfiguration without time-consuming manual reallocation, as the controller automatically manages device assignments.
Solution Approach 2:
The patent creates universal manufacturing process instances that can utilize different industrial devices based on allocation. This multi-functionality allows the same process instance to operate with different device configurations, enabling rapid adaptation to changing requirements without time loss.
Data Source
AI summary
Embodiments of a system including at least one access node configured to wirelessly transmit and receive signals to and from industrial devices within at least two cells of a cellular communications network deployed within a manufacturing facility; and a computer system. The computer system includes an interface connected to transmit and receive signals to and from the access node; and processing circuitry configured to: define a manufacturing process instance, MPI, identifying manufacturing operations necessary to perform a predetermined manufacturing process; allocate one of more of the industrial devices to the MPI, each allocated industrial device configured to perform at least one of the identified manufacturing operations; and implement an Controller configured to control each of the industrial devices allocated to the MPI to cooperatively perform the predetermined manufacturing process.