Hybrid Plant Module Integration via Protocol Translation Gateway
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Solution Overview
Problem
Hybrid modular plants combining discrete and process manufacturing elements face challenges in integrating modules described by different standards, such as MTP and PackML, due to incompatible operation and communication methods.
Innovation Solution
A generic approach is implemented to create a transparent interface between the orchestration layer and modules using automated or semi-automated mapping and runtime translation, enabling interoperability through a common communication protocol like OPC UA, allowing for the integration of mixed-standard modules into a unified orchestration layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modules described by different standards (MTP and PackML) are integrated into a hybrid modular plant, then interoperability and mixed operation are enabled, but integration complexity and communication compatibility issues increase
Solution Approach 1:
The patent introduces a gateway as an intermediary component that mediates between modules described by different standards (MTP and PackML). The gateway performs protocol conversion and data mapping, translating communication between the two standards to enable interoperability while isolating the complexity of standard conversion from the individual modules.
Solution Approach 2:
The gateway is designed with multi-functionality to handle both MTP and PackML standards simultaneously. It can receive data from modules using either standard, perform appropriate translations, and route data to the correct destinations, making the hybrid plant architecture universally compatible with multiple communication protocols.
2Adaptability or versatility
If automated or semi-automated mapping and runtime translation are implemented, then interoperability between standards is enabled, but system complexity and computational overhead increase
Solution Approach 1:
The system performs preliminary actions by pre-defining mapping relationships between MTP and PackML data structures during system configuration. Common data points and communication patterns are pre-translated and stored as mapping rules, so that runtime translation only requires looking up predefined mappings rather than performing complex real-time conversions.
Solution Approach 2:
The gateway creates simplified copies or representations of data from one standard format in the target format. Instead of performing complex real-time translations of all data structures, the gateway maintains copied versions of critical data in both MTP and PackML formats, enabling fast interoperability while reducing computational overhead.
3Ease of operation
If a transparent interface between orchestration layer and modules is created, then access to hybrid automation is facilitated, but integration costs and implementation effort increase
Solution Approach 1:
The gateway implements self-service capabilities by automatically detecting the communication standard being used by connected modules and autonomously configuring the appropriate translation rules. This self-configuration reduces the need for manual integration work and lowers implementation costs, while still providing transparent access to hybrid automation functionality.
Data Source
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AI summary
The invention provides a method of integrating modules into a hybrid modular plant comprising a discrete manufacturing part and a continuous manufacturing part. The method comprises integrating the discrete part into the continuous part, comprising constructing (401; 501) at least one module definition file (400, 500) mapping one or more discrete-part units (202) of the discrete part to a continuous-part module (102) and importing (402; 502) the module definition file (400, 500) into an orchestration layer (108) of the continuous part. Alternatively, the method comprises integrating the continuous part into the discrete part, comprising constructing one or more interfaces (610) representing each continuous-part module (102) as one or more respective discrete-part units (202).