Flexible Automation Control Configuration via Segmented Databases
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Solution Overview
Problem
Existing automation systems with rigid control configurations face challenges in accommodating hardware modifications, leading to increased time and costs for reconfiguration, especially in modularly constructed systems where changes in input/output units and communication couplers require extensive adaptation of control projects.
Innovation Solution
A method and system for configuring a control device in a modularly constructed automation system with a flexibly expandable hardware structure, using a programming tool to register hardware modifications via 'FlexConf.ini' software, set the control device to a flexible configuration mode, and transmit modification information to adapt configuration data, enabling parameterization and startup in the 'RUN' mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid control configuration is used to ensure system stability and reliability, then the control system operates reliably according to the planned hardware, but any hardware modifications require extensive reconfiguration of the control project, increasing time and costs
Solution Approach 1:
The patent segments the control configuration into two independent parts: a baseline configuration that ensures system reliability and a modification configuration that handles hardware changes. The modification configuration is stored separately in a database and can be applied without affecting the baseline configuration, thus maintaining reliability while enabling adaptability.
Solution Approach 2:
The patent performs preliminary actions by pre-storing multiple modification configurations in a database before hardware changes occur. When hardware modifications are needed, the appropriate pre-stored configuration is retrieved and applied, eliminating the need for extensive reconfiguration work and reducing both time and costs.
2Adaptability or versatility
If the control project is extensively adapted to accommodate hardware modifications, then the system becomes flexible to hardware changes, but the reconfiguration process requires significant time and resources
Solution Approach 1:
The patent performs preliminary actions by pre-storing multiple modification configurations in a database before hardware changes occur. When hardware modifications are needed, the appropriate pre-stored configuration is retrieved and applied, eliminating the need for extensive reconfiguration work and reducing both time and costs.
Solution Approach 2:
The patent uses copying by storing modification configurations as reusable templates in a database. These configurations can be copied and applied to different hardware modification scenarios without creating them from scratch each time, significantly reducing reconfiguration time and resource requirements.
3Reliability
If all project-planned input/output units are connected and parameterized to ensure proper system operation, then the control system starts up successfully, but the system cannot accommodate customer-specific expansions or hardware changes
Solution Approach 1:
The patent segments the control configuration into a baseline configuration that ensures reliable startup with the planned hardware, and a separate modification configuration that handles customer-specific expansions. The modification configuration is stored in a database and applied independently, allowing the system to maintain startup reliability while accommodating hardware changes.
Solution Approach 2:
The patent introduces dynamics by making the control configuration changeable through a database-driven approach. The system can dynamically switch between baseline and modification configurations based on the actual hardware setup, enabling both reliable operation with planned hardware and adaptability to customer-specific expansions.
4Adaptability or versatility
If the control configuration is revised and transmitted anew to accommodate hardware changes, then the system adapts to new hardware configurations, but the reconfiguration process increases time and costs
Solution Approach 1:
The patent performs preliminary actions by pre-storing multiple modification configurations in a database before hardware changes occur. When hardware modifications are needed, the appropriate pre-stored configuration is retrieved and applied, eliminating the need for extensive reconfiguration work and reducing both time and costs.
Solution Approach 2:
The patent uses copying by storing modification configurations as reusable templates in a database. These configurations can be copied and applied to different hardware modification scenarios without creating them from scratch each time, significantly reducing reconfiguration effort and costs.
Data Source
AI summary
Exemplary embodiments are directed to a system and method for configuring a control device in an automation system. The system including a hardware structure, and a programming tool connected to the hardware structure and the control device. The programming tool is configured to transmit a control program and configuration files to the control device, and store a control project in memory. The programming tool registers modifications of the hardware devices using software “FlexConf.ini” as modification information and sets the control device to a mode “control with flexible configuration” via a parameter “FlexControl”. The programming tool also determines a type for transmitting the modification information in the parameter “FlexControl”, and transmits the modification software with the modification information stored therein in accordance with the transmission type set in the parameter “FlexControl” to the control device. The control device then parameterizes the hardware devices and transitions into a “RUN” operating mode.