Integrated Process Control for Workstations and Transport Fleets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control systems for facilities with automated workstations and transport vehicles lack efficient integration and synchronization, leading to suboptimal planning and execution of processes and movements, which can result in inefficiencies and potential deadlocks.
Innovation Solution
A process controller system that integrates processing means for planning and executing workstation processes, fleet means for managing transport vehicle movements, and work means for communication with both, using software and hardware technologies to synchronize and optimize processes and movements in a deterministic and predictable manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate control systems are used for workstations and transport vehicles, then system simplicity is maintained, but integration and synchronization efficiency deteriorate
Solution Approach 1:
The patent merges separate control systems for workstations and transport vehicles into a unified process controller. The controller integrates a processing means for managing workstation processes, a fleet means for managing transport vehicle movements, and a work means arrangement for communication with both systems, enabling centralized coordination and eliminating synchronization inefficiencies.
2Reliability
If centralized control is implemented for both workstations and transport vehicles, then process and movement synchronization is improved, but system complexity increases
Solution Approach 1:
The centralized controller is segmented into distinct functional modules: a processing means for workstation process management, a fleet means for transport vehicle movement management, and a work means arrangement for communication interfaces. This modular segmentation reduces architectural complexity while maintaining effective centralized coordination.
Solution Approach 2:
The work means arrangement acts as an intermediary communication layer between the processing means, fleet means, and external systems (workstations and transport vehicles). This mediator component standardizes communication protocols and data exchange, simplifying the overall system architecture while enabling reliable synchronization.
3Reliability
If deterministic planning is used for processes and movements, then predictability is improved, but adaptability to dynamic changes deteriorates
Solution Approach 1:
The control system implements dynamic planning capabilities that allow deterministic schedules to be adjusted in real-time. The processing means and fleet means can generate initial deterministic plans for workstation processes and transport vehicle movements, then dynamically replan when disturbances or changes occur, maintaining both predictability and adaptability.
Solution Approach 2:
The system incorporates feedback mechanisms where the processing means monitors workstation process status and the fleet means monitors transport vehicle status in real-time. This feedback enables the controller to detect deviations from planned schedules and trigger adaptive replanning while maintaining overall deterministic operation.
Data Source
AI summary
A process control system for a facility that has a station arrangement including at least one at least partially automated working station and a vehicle arrangement including at least one at least partially automated transport vehicle for transporting material to be conveyed to, in and/or from the station arrangement. The process control system includes a process means for planning, implementing and/or observing, particularly monitoring processes of the station arrangement, a fleet means for planning, implementing and/or observing, particularly monitoring movements of the vehicle arrangement, and a working means arrangement with at least one working means for controlling and/or monitoring at least one working station of the station arrangement. The process and fleet means and/or the process means and the working means arrangement and/or the fleet means and the working means arrangement are configured to communicate with each other.