Distributed Controller Recipe Initialization for Batch Automation
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Solution Overview
Problem
Conventional automation solutions for batch production processes in processing facilities, such as chemical and pharmaceutical plants, face challenges in meeting aggressive real-time requirements due to resource exhaustion and high maintenance costs, particularly in environments requiring low error rates and scalability.
Innovation Solution
A system and method that utilize controllers to initialize and execute process steps from a master recipe dynamically, optimizing resource allocation by only loading necessary data and anticipating future resource needs, reducing data duplication and latency through modular, real-time control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional automation solutions using supervisory personal computer technology are used to control production processes, then the system is easier to implement and maintain, but the system cannot meet aggressive real-time requirements and experiences resource exhaustion
Solution Approach 1:
The patent segments the automation system into multiple distributed controllers instead of using a single supervisory personal computer. Each controller handles specific real-time control tasks independently, eliminating resource exhaustion at a single point and meeting aggressive real-time requirements through distributed processing.
Solution Approach 2:
The patent introduces a controller network as an intermediary layer between the supervisory system and production equipment. This mediator distributes control tasks across multiple nodes, providing both real-time control capability and system scalability without requiring complex centralized processing.
2Productivity
If more controllers and processing power are added to meet real-time requirements, then real-time control capability improves, but maintenance costs and system complexity increase
Solution Approach 1:
The patent employs universal controller modules that can perform multiple functions across different production stages. These standardized controllers can be deployed throughout the system, reducing the variety of components that need to be maintained and lowering overall maintenance costs despite increased system scale.
Solution Approach 2:
The patent uses replicated controller units with identical software and hardware configurations. This copying approach simplifies maintenance because replacement units can be quickly deployed without complex reconfiguration, and failures can be addressed through standardized procedures applicable to all copies.
3Speed
If data is pre-loaded into controller memory to enable fast execution, then real-time response speed improves, but memory resources are consumed and data duplication occurs
Solution Approach 1:
The patent performs preliminary actions by pre-compiling control recipes and preparing execution pathways before real-time execution. Controllers load only essential instruction sets and parameters into memory in advance, enabling fast execution without duplicating entire data sets. This allows rapid response while conserving memory resources through selective pre-loading.
Data Source
AI summary
A method includes initializing, at a first controller, at least one process step of a control recipe from a master recipe associated with a batch process in response to detection of an event associated with the batch process. The method also includes executing, at the first controller, the at least one process step of the control recipe. The method further includes initializing, at the first controller, at least one second process step of the control recipe while executing the at least one process step of the control recipe. Initializing the at least one process step of the control recipe from the master recipe may include copying only a portion of the master recipe into the control recipe that is needed to begin execution of the control recipe.