Function Module I/O Verification for Modular Plant Design Errors
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Solution Overview
Problem
In modular industrial plants, design errors in function modules often go undetected until later stages, leading to significant cost increases and operational issues, as existing design tools lack consistency and conflict checks for input/output channels.
Innovation Solution
A computer-implemented method for verifying function module design in modular industrial plants, using a ruleset to check input/output channels and their connections, preventing the use of faulty modules and alerting designers to errors, with additional checks for dependencies and service states to ensure correct functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If design verification is performed manually without automated ruleset checking, then device complexity is reduced, but manufacturing precision deteriorates due to undetected design errors
Solution Approach 1:
The patent applies preliminary action by performing design verification checks before the actual plant commissioning and operation. The ruleset validation is executed during the engineering phase, specifically when function modules are being designed and configured, rather than waiting for later testing phases. This early detection prevents errors from propagating to subsequent implementation stages.
Solution Approach 2:
The patent introduces an intermediary verification system that acts as a mediator between the design tool and the final plant implementation. The ruleset checking mechanism serves as this intermediary, automatically validating I/O channel configurations, connections, and data types without requiring manual inspection. This intermediary layer catches design errors that would otherwise pass through to commissioning.
2Reliability
If comprehensive ruleset checking is implemented, then reliability improves by detecting errors early, but loss of time increases due to additional verification steps
Solution Approach 1:
The verification system applies self-service by automatically performing all validation checks without requiring manual intervention from engineers. The ruleset checking mechanism autonomously validates I/O channel configurations, detects inconsistencies, and reports errors. This automation eliminates the need for time-consuming manual review processes while maintaining comprehensive verification coverage.
Solution Approach 2:
The patent replaces manual mechanical verification processes with automated computational checking. Instead of engineers manually reviewing I/O channel connections and configurations, the system uses automated ruleset validation algorithms to perform the same function. This substitution dramatically reduces verification time while improving consistency and reliability of the checking process.
3Ease of manufacture
If design errors are detected late during factory acceptance test, then ease of operation is maintained, but loss of substance increases due to higher correction costs
Solution Approach 1:
The patent applies preliminary action by detecting and correcting design errors during the engineering phase, specifically during function module design and configuration, rather than waiting for factory acceptance testing or plant commissioning. The ruleset validation is executed as part of the design process, allowing errors to be identified and corrected when the cost of modification is minimal and the system is still being configured.
Data Source
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AI summary
A computer-implemented method (100) for verifying the design of a function module (2) for use in a modular industrial plant (1), wherein the function module (2) comprises control logic configured to accept sensor data and actuate a physical process module such that at least one process quantity and/or state quantity of the process module can be kept near a desired set-point value, as well as logic to accept commands from a superordinate management system, and communication between logics, as well as between the function module (2) and the rest of the modular industrial plant (1), is by input/output channels (31-35) representing parameters and/or variables, the method comprising the steps of: • obtaining (110) a ruleset (4) comprising at least requirements for I/O channels (31-35) and their connections that are necessary conditions for the function module (2) to perform its intended function in the modular industrial plant (1); • checking (120) whether the input/output channels (31-35) of the function module (2) and their connections meet the rules in the ruleset (4); and • in response to determining that at least one rule in the ruleset (4) is not met, determining (130) that the design of the function module (2) has an error, and preventing (190) use of the function module (2) in the modular industrial plant (1).