Distributed Batch Recipe Control With Centralized Master Reuse
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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 distributed controllers, eliminating the need for duplication and manual transfers, allowing seamless reuse across multiple controllers and sites, and enabling automatic deletion after batch operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If master recipes are manually transferred and duplicated across multiple controllers in distributed modular automation systems, then each controller can execute batch operations independently, but engineering efforts increase, validation complexity increases, and regulatory compliance costs increase
Solution Approach 1:
The patent implements automatic copying of master recipes from a centralized repository to multiple distributed controllers. The system creates and manages recipe copies automatically, eliminating manual transfer processes. This allows independent batch execution at each controller while reducing engineering efforts and validation complexity associated with manual recipe duplication.
Solution Approach 2:
The system performs preliminary actions by pre-configuring and validating master recipes in a centralized repository before distribution. Recipes are prepared, validated, and staged in advance, then automatically deployed to controllers when needed. This preliminary validation reduces compliance costs and ensures consistency across distributed systems.
2Reliability
If master recipes are stored locally at each controller, then batch operations can execute independently without network dependency, but network bandwidth consumption increases and recipe consistency becomes difficult to maintain
Solution Approach 1:
The patent segments recipe management into two parts: a centralized repository for master recipe storage and validation, and distributed controllers for local execution. This segmentation allows controllers to maintain local copies for reliable independent operation while the centralized system manages updates efficiently, reducing unnecessary network bandwidth consumption.
Solution Approach 2:
The system introduces a centralized recipe repository as an intermediary between recipe authoring and controller execution. This intermediary manages recipe distribution, validation, and updates, allowing controllers to obtain recipes efficiently without direct peer-to-peer communication, thus reducing network bandwidth consumption while maintaining reliability.
3Productivity
If manual transfer and duplication of master recipes is performed, then recipe distribution across controllers is achieved, but engineering efforts increase and regulatory compliance costs increase
Solution Approach 1:
The system implements self-service automation where the recipe management system automatically performs duplication, validation, and distribution of master recipes across controllers without manual intervention. This self-service capability dramatically increases recipe distribution speed while reducing engineering time and compliance costs associated with manual processes.
Solution Approach 2:
The patent changes the operational parameters of recipe management from manual processes to automated electronic distribution. By transforming the system from manual copying to automated digital distribution with automatic validation, recipe distribution speed increases significantly while engineering time and compliance costs are reduced.
4Ease of operation
If master recipes are duplicated across multiple controllers, then each controller has local recipe availability, but validation challenges increase and regulatory compliance issues arise
Solution Approach 1:
The system uses controlled copying where master recipes are automatically copied from a centralized validated repository to distributed controllers. The copying process includes automatic validation to ensure consistency, maintaining manufacturing precision while providing local recipe availability for ease of operation.
Solution Approach 2:
The patent implements feedback mechanisms where the centralized repository monitors and validates recipe copies at distributed controllers. This feedback loop ensures recipe consistency across all controllers, maintaining manufacturing precision while allowing local availability for ease of operation.
Data Source
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.