Distributed Batch Recipe Control Across Modular Automation Units
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Solution Overview
Problem
Current batch automation control systems face inefficiencies in managing and distributing master recipes across multiple server-based and controller-based platforms in modular automation, leading to duplication, validation challenges, and regulatory compliance issues, which hinder flexibility and scalability in process manufacturing.
Innovation Solution
A method where a single master recipe is stored in an enterprise database and automatically loaded into targeted controllers, eliminating the need for duplication and manual transfers, allowing seamless reuse across multiple controllers and sites, and enabling automatic generation of control recipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If master recipes are manually transferred and duplicated across multiple controllers, then each controller can execute batch operations independently, but this leads to duplication efforts, validation challenges, and increased complexity
Solution Approach 1:
The system creates a centralized copy of master recipes in the enterprise database that can be automatically distributed to multiple controllers. This eliminates manual duplication efforts and ensures all controllers have access to the same validated recipe version, reducing complexity while maintaining execution reliability.
Solution Approach 2:
The patent merges the recipe storage and distribution function into a centralized enterprise database that serves all controllers. This consolidation eliminates the need for separate manual transfer processes and validation procedures at each controller, reducing overall system complexity while ensuring reliable batch execution.
2Adaptability or versatility
If master recipes are stored locally in each controller, then controllers can operate independently, but this increases duplication efforts and reduces flexibility for updates
Solution Approach 1:
The system performs preliminary validation and approval of master recipes in the centralized enterprise database before distribution. This preliminary action ensures that only validated recipes are made available to controllers, eliminating the need for time-consuming validation procedures at each controller and enabling rapid updates across the entire system.
Solution Approach 2:
The enterprise database serves as a universal repository that stores, validates, and distributes master recipes to multiple controllers simultaneously. This multi-functional approach eliminates the need for separate local storage and validation processes at each controller, reducing time loss while improving update flexibility across the entire manufacturing system.
3Productivity
If manual transfer methods are used for distributing master recipes, then system compatibility is maintained, but human error increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical transfer processes with an automated electronic distribution system. The enterprise database automatically distributes master recipes to controllers through electronic communication, eliminating human involvement in the transfer process. This substitution increases productivity while preventing human errors such as transcription mistakes or version confusion.
4Ease of operation
If multiple copies of master recipes are maintained across controllers, then local execution is enabled, but network bandwidth usage increases and synchronization becomes complex
Solution Approach 1:
The system implements periodic synchronization where controllers receive master recipe updates from the enterprise database only when changes are made. This periodic action approach enables local execution capability while minimizing network bandwidth consumption, as controllers do not continuously communicate but rather synchronize only when necessary.
Data Source
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AI summary
A method and system are provided for distributing master recipes for process control systems comprising storing a single master recipe on a server having an enterprise database and communicating said single master recipe to each of a plurality of manufacturing units. Control recipes are seamlessly created using common master recipes across multiple process plants to deliver consistent product quality with enough flexibility and interoperability in accordance with ISA S88 batch standards.