Modular Process Installation Configuration Without Central DCS
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Solution Overview
Problem
Existing modular production systems require a central control system, which limits flexibility and adaptability to changing production conditions, as each autonomous module must have self-contained functions for interconnection and service coupling, which is often not feasible in reality.
Innovation Solution
A decentralized system where installation modules are connected mechanically and electrically, forming data exchange couplings via communication protocols, with a central server storing configuration data and each module having access paths for configuration, enabling autonomous operation and communication without a central DCS system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a central control system is used to integrate modules, then centralized control and coordination is achieved, but flexibility and adaptability to changing production conditions deteriorates
Solution Approach 1:
The control system is segmented into autonomous modules, each with its own control capabilities. Instead of one centralized controller, multiple independent control units manage different process segments, enabling local decision-making and faster adaptation to changes while maintaining system-wide coordination through standardized interfaces.
Solution Approach 2:
Each module is designed to be self-sufficient with embedded control logic and decision-making capabilities. Modules can autonomously adjust their operation based on local conditions and communicate requirements to other modules, reducing dependency on centralized control and enabling rapid response to changing production conditions.
2Adaptability or versatility
If autonomous modules are designed with self-contained functions for interconnection, then module independence is improved, but device complexity deteriorates
Solution Approach 1:
Standardized interfaces and communication protocols are implemented across all modules, enabling universal interconnection. The same interface standards allow different module types to connect and interact through common rules, reducing the complexity of interconnections while maintaining module independence and enabling flexible system configuration.
3Ease of operation
If a central DCS system is used for configuration and control, then centralized management is achieved, but engineering time and system complexity deteriorates
Solution Approach 1:
Module configurations, control logic, and communication protocols are pre-defined and standardized during the design phase. This preliminary preparation allows modules to be quickly deployed and integrated without extensive on-site engineering and configuration work, significantly reducing engineering time while maintaining centralized management capabilities through standardized interfaces.
Data Source
AI summary
A system and method includes integrating a plurality of installation modules each having at least one process-technical unit which, besides hardware, also houses control technology, to form a modularly constructed overall installation. The installation modules are arranged three-dimensionally and, according to the description of the overall installation, are connected mechanically and electrically to one another. Between the installation modules, at least one coupling for data exchange is formed via one or more communication protocols. A configuration of the overall installation is assembled and stored on a central server unit having a data link to the installation modules. Each installation module is allocated at least one access path to the configuration. After the installation modules have been started, each installation module forms a connection to the configuration via the access path, reads configuration data respectively intended for the installation module to be read via the access path and, in accordance with the configuration data read, forms the communication links to at least one further installation module, wherein links are formed between individual data objects and also service interfaces are requested, and the installation modules provide the relevant function thereof to the outside via data points and services.