Modular Automation Framework for Faster Filling Line Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automation frameworks for filling machines and related systems face challenges in efficiently integrating new functionalities, leading to increased downtime, high costs, and limited responsiveness to customer needs due to time-consuming customization and resource-intensive troubleshooting processes.
Innovation Solution
The method involves isolating and independently accessing control functionalities within the automation framework, generating combined control functionalities, and using an application manager to communicate with control units, allowing for efficient integration of new hardware and software, improved re-usability, and facilitated maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new functionalities are integrated into the automation framework through customization, then the system can meet customer needs, but the implementation time increases and machine downtime increases
Solution Approach 1:
The automation framework is segmented into independent, modular control functionalities that can be individually activated or deactivated. Each control functionality is isolated and can be managed separately through the application manager, allowing new functionalities to be integrated without affecting the entire system. This modular architecture enables selective implementation of specific features without requiring system-wide customization.
Solution Approach 2:
The framework provides a universal application manager that can manage diverse control functionalities across multiple devices through a common interface. The system is designed to handle various types of control functionalities (production control, service functions, troubleshooting) in a unified manner, allowing new functionalities to be integrated into the existing framework without requiring separate customization for each function.
2Reliability
If the entire production system is taken offline for troubleshooting or integration, then service needs can be addressed, but the throughput of the production line decreases
Solution Approach 1:
The system separates control functionalities into independent modules that can be accessed and modified individually. The application manager enables service personnel to isolate and work on specific control functionalities (such as troubleshooting a particular device or integrating new hardware) without taking the entire production system offline. This segmentation allows parallel operation of production and maintenance activities.
Solution Approach 2:
The application manager acts as an intermediary layer between the control unit and the various control functionalities. It provides a standardized interface that allows service operations to be performed on isolated functionalities without disrupting the overall system operation. The mediator enables selective access to specific devices or functions while maintaining system-wide productivity.
3Adaptability or versatility
If control functionalities are interconnected, then system integration is achieved, but the complexity of managing and troubleshooting increases
Solution Approach 1:
While maintaining system integration, the framework segments control functionalities into independently manageable units. Each control functionality is encapsulated with its own status and control interface, allowing the system to remain integrated at the framework level while presenting a simplified, modular structure for management and troubleshooting. The application manager provides a high-level view that manages complexity by abstracting individual functionality details.
4Adaptability or versatility
If customization is performed for each machine to integrate new functionalities, then specific customer needs are met, but costs increase
Solution Approach 1:
The framework implements a universal application manager that provides standardized functionality across different machines and devices. Instead of customizing each machine individually, the same application manager can manage diverse control functionalities across the entire system. New functionalities can be deployed universally through the framework, reducing per-machine customization costs while maintaining the ability to meet specific customer needs through configuration rather than structural modification.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for controlling an automation framework in a manufacturing system for containers with food content is disclosed comprising isolating at least first and second control functionalities of a plurality of devices from each other so that the first and second control functionalities are independently accessible to a control unit as respective first and second isolated control functionalities, generating a set of combined control functionalities for the first and/or the second device based on the first and second sets of isolated control functionalities, wherein the set of combined control functionalities are individually accessible to a control unit, and controlling at least the first and/or second device of the plurality of devices based on at least the set of combined control functionalities with an application manager configured to communicate with the control unit. An associated automation framework is also disclosed.