Real-Time Change Profile Control for Complex Automation Processes
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Solution Overview
Problem
Modern, highly complex automation processes face challenges in ensuring real-time capability due to the large number of process parameters, which can lead to inefficient optimization and unpredictable termination times of numerical approximation methods.
Innovation Solution
A method is introduced that combines a real-time capable detection method based on non-linear optimization with a numerical algorithm to determine a change profile, ensuring that the automation process is controlled within a predetermined time frame by adjusting a profile function to meet boundary and secondary conditions, and using a fallback profile if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerical approximation methods are used to optimize process parameters, then optimization quality can be guaranteed, but real-time operation cannot be ensured due to unpredictable termination times
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing optimal parameter combinations in lookup tables before real-time operation. During runtime, the system directly retrieves pre-computed solutions rather than performing numerical approximation, thus guaranteeing both optimization quality and real-time termination.
Solution Approach 2:
The system prepares fallback strategies and alternative parameter sets in advance. When the primary optimization path cannot be completed within the time budget, pre-prepared alternative solutions ensure continuous operation without violating real-time constraints, cushioning against the unpredictable termination times of numerical methods.
2Adaptability or versatility
If the number of process parameters is increased to handle complex automation processes, then process control capability is improved, but computational complexity increases making real-time control difficult
Solution Approach 1:
The patent segments the large set of process parameters into smaller, independent groups or modules. Each segment can be optimized separately using numerical approximation methods, and the results are combined to form the complete solution. This reduces the computational complexity of each optimization task while maintaining the ability to handle complex overall processes.
Solution Approach 2:
Parameter groups are pre-processed and their interrelationships are pre-analyzed offline. This preliminary segmentation and analysis reduces the real-time computational burden by preparing the problem structure in advance, allowing the system to handle complex parameter sets without exceeding real-time computational limits.
3Manufacturing precision
If numerical approximation methods are used to adapt profile functions, then optimization criteria are satisfied, but the method cannot terminate within a guaranteed maximum time period
Solution Approach 1:
The system uses simplified, computationally inexpensive approximation methods for real-time profile adaptation instead of expensive numerical optimization. These lighter methods may provide slightly lower precision but guarantee termination within the time budget, accepting a trade-off between precision and real-time performance.
Solution Approach 2:
Complex profile adaptation is performed offline in advance, storing the results for real-time retrieval. The preliminary high-precision adaptation done during offline processing eliminates the need for time-consuming numerical approximation during real-time operation, ensuring both precision and timely completion.
Data Source
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AI summary
The invention relates to a method (100) for controlling an automation process in real time on the basis of a change profile P of at least one process variable PV, the method steps comprising: determining (101) a first change profile P1 by means of a recognition method having real-time capability and based on a nonlinear optimization process taking account of at least one boundary condition BC of the process variable PV, determining (103) a second change profile P2 by means of a numerical algorithm on the basis of the first change profile P1, comprising: adapting (105) a selected profile function PF to the first change profile P1 by means of a numerical adaptation process, and identifying (107) the adapted profile function PF as a second change profile P2, checking 109 whether the second change profile P2 satisfies at least one secondary condition SC of the process variable PV, controlling (111) the automation process on the basis of the second change profile P2 if the second change profile P2 satisfies the at least one secondary condition SC, and controlling (113) the automation process on the basis of a predetermined default profile P3 if the second change profile P2 does not satisfy the at least one secondary condition SC.