Distributed Power Unit Control With Integrated Real-Time Diagnostics
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Solution Overview
Problem
Existing power plant control systems are inflexible and specialized, making them unsuitable for the shift towards distributed energy generation and the integration of renewable sources, requiring more efficient diagnostic and automation solutions for smaller, decentralized power units.
Innovation Solution
A combined automation and diagnostic system with separate realtime and non-realtime components connected by a communication link, allowing for efficient integration of diagnostic methods and automation tasks, and enabling the use of cloud applications on field devices with high sampling rates, while reducing hardware and cabling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a central hierarchically structured process control system is used for large power plants, then deterministic real-time control and monitoring are achieved, but the system becomes inflexible and unsuitable for distributed energy generation
Solution Approach 1:
The system is segmented into multiple independent control nodes, each capable of autonomous real-time control for individual power generating units. These nodes are distributed across the network rather than centralized, allowing each unit to operate independently while maintaining overall system coordination through the communication network.
Solution Approach 2:
The control system is designed as a universal platform that can manage diverse power generating units (wind turbines, solar fields, bio-gas plants) with different characteristics. The standardized communication protocols and modular architecture enable the same system to adapt to various unit types without requiring specialized dedicated control systems for each.
2Productivity
If specialized subsystems are used in traditional control systems, then specific functions are optimized, but the system complexity increases and integration becomes difficult
Solution Approach 1:
Previously separate control and monitoring functions are merged into integrated control nodes. Each node combines real-time control capabilities, diagnostic functions, and communication interfaces in a single modular unit, reducing the number of discrete components and simplifying system integration while maintaining functional optimization.
Solution Approach 2:
The system employs a nested modular architecture where standardized control nodes can be hierarchically organized. Individual unit controllers are nested within group controllers, which are nested within the overall plant management system, allowing functional optimization at each level while simplifying integration through standardized interfaces.
3Reliability
If separate diagnostic systems are used to monitor critical operating states, then diagnostic capability is improved, but hardware costs and system complexity increase
Solution Approach 1:
Diagnostic functions are merged into the same control nodes that perform real-time control. The control nodes include integrated diagnostic software modules that monitor operating states, detect anomalies, and provide predictive maintenance capabilities without requiring separate dedicated diagnostic hardware systems.
Solution Approach 2:
The control nodes are designed as multi-functional units that simultaneously perform real-time control, data acquisition, diagnostic monitoring, and communication functions. This universal design eliminates the need for separate specialized diagnostic systems while maintaining comprehensive monitoring capability across all power generating units.
Data Source
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AI summary
The invention is related to a system for operation and control of a plurality of power generating units. It comprises of an automation system and a diagnostic system combined to one compact device. Thus a combined system for diagnostics and automation is provided, which is assembled by at least one realtime component/module and at least one non-realtime component/module, which are connected by a communication link. The realtime component is connected to I/O modules in the field and works on a higher sampling rate than the non-realtime component. The realtime component is designed to execute both, diagnostics and automation tasks. The non-realtime component comprises of at least one virtual machine containing application software in their native operating system environment and being embedded in a host operating system. The inventive system is advantageously designed to integrate more diagnostic methods and applications into the hardware near the field and to provide an easy combination with automation.