Configurable Logic in Functional Modules for Modular Plant Orchestration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional automation systems for modular technical installations face complexity in orchestrating interactions between functional modules, leading to high communication efforts and load limits at the control level, especially when dealing with a large number of modules.
Innovation Solution
A functional module with a configurable logic unit that can receive and adapt additional rules and interconnections from external communication partners, enabling dynamic interaction with other modules without altering its structure, using OPC UA communication and a visualization system for efficient integration and orchestration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of functional modules are integrated into a technical installation, then the functionality and versatility of the installation is improved, but the communication effort and load on the control level increases significantly
Solution Approach 1:
The patent divides the control architecture into hierarchical levels: a higher-order control level that manages orchestration and a decentralized control level within each functional module that handles local control logic. This segmentation distributes the communication load, allowing multiple modules to operate autonomously while reducing the burden on the central control level.
Solution Approach 2:
The patent implements dynamic configurability where control logic can be transferred between the higher-order control level and individual functional modules at runtime. This allows the system to adaptively distribute control responsibilities based on operational needs, optimizing communication efficiency while maintaining versatility.
2Device complexity
If classic automation concepts are used for orchestrating modular installations, then the system structure is simplified, but the complexity of project planning and operation increases
Solution Approach 1:
The patent enables functional modules to autonomously manage their own control logic and interconnections. Each module can independently receive and execute control instructions, and the system automatically handles the orchestration of inter-module communications, reducing the need for manual project planning and simplifying operational management.
Solution Approach 2:
The patent creates a universal orchestration framework that can manage diverse functional modules through standardized interfaces. The higher-order control level uses a unified approach to coordinate different module types, eliminating the need for complex custom integration work for each specific module configuration.
3Reliability
If control logic is permanently stored in functional modules, then the reliability and stability of module operation is improved, but the adaptability to changing operational requirements deteriorates
Solution Approach 1:
The patent implements a dynamic control architecture where the distinction between permanent and temporary control logic is blurred. Control logic can be permanently stored for reliability but can also be dynamically transferred or modified from the higher-order control level to adapt to changing requirements, combining both reliability and adaptability.
Solution Approach 2:
The system continuously monitors operational requirements and can dynamically adjust the distribution of control logic between the higher-order control level and individual functional modules. This feedback mechanism ensures that control logic remains both stable for reliable operation and adaptable to changing conditions.
Data Source
AI summary
A functional module includes at least one technical object for performing a technical process, a control unit which control the technical object based on previously determined rules and interconnections that are being permanently stored in the control unit, a communication unit which interchanges data with external communication partners, wherein the functional module has a configurable logic unit which uses the communication unit to receive additional, variably predefinable rules and interconnections from an external communication partner and to take the additional, variably predefinable rules and interconnections as a basis for supplementing the rules and interconnections previously determined in the control unit with respect to an interaction of the functional module with at least one further functional module.