Modular Facility Control with OPC UA for Fast Reconfiguration

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Solution Overview

Problem

Conventional production facilities struggle with fluctuating product demands and short product lifecycles due to insufficient modular control integration, leading to inefficient operations and complex reconfiguration processes.

Innovation Solution

A modular technical facility with autonomous controllers and an external interface that includes a server with static and dynamic information structures, allowing for simplified integration and communication of modules, reducing control effort and enabling efficient PFE engineering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional production facilities are designed for continuous operation optimized for a certain production rate, then production efficiency is improved, but adaptability to fluctuating product quantities deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoidadaptability to fluctuating product quantities

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The facility is divided into independent, interchangeable modules that can be individually added, removed, or reconfigured. Each module contains its own autonomous controller, allowing the system to be scaled and adapted in discrete units to match fluctuating production demands without reconfiguring the entire facility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a fixed, continuous operation design to a dynamic modular architecture where modules can be dynamically added or removed based on real-time production requirements. The autonomous controllers enable each module to adapt its operation independently, providing flexibility while maintaining overall system efficiency.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If ordinary facilities for batch operation are used to handle fluctuating demands, then adaptability is improved, but production efficiency deteriorates due to unproductive times

Engineering Contradiction:

Improveability to handle fluctuating demandsVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The modular architecture with autonomous controllers enables continuous operation even when individual modules are being added, removed, or maintained. Other modules can continue producing without interruption, eliminating the unproductive downtime characteristic of traditional batch operations while maintaining adaptability to demand fluctuations.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If hardware modifications are made to add or modify system capacity, then production capacity is improved, but control reconfiguration complexity increases

Engineering Contradiction:

Improveproduction capacityVSAvoidcontrol reconfiguration complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each module includes an autonomous controller that is pre-configured and self-sufficient. When modules are added or modified, they automatically integrate into the system through standardized interfaces without requiring complex central control reconfiguration. The autonomous controllers handle their own operations and communicate through simple message exchanges, dramatically reducing control integration complexity.

Inventive Principle:

Principle #25Self-service

4Adaptability or versatility

If control software is reprogrammed to accommodate hardware modifications, then system functionality is improved, but implementation time increases

Engineering Contradiction:

Improvesystem functionalityVSAvoidcontrol reprogramming time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The autonomous controllers use a universal, standardized software architecture that can accommodate different hardware configurations and production scenarios. The same controller framework handles diverse module types and operations, eliminating the need for custom programming for each modification and enabling rapid system adaptation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Ease of manufacture

If outdated control hardware is used, then initial cost is reduced, but ability to provide required functions deteriorates

Engineering Contradiction:

Improveinitial costVSAvoidability to provide required functions

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The autonomous controllers are pre-configured with comprehensive functionality and standardized interfaces during manufacturing. This preliminary setup ensures that even basic control hardware can provide advanced functions out of the box, eliminating the need for expensive upgrades or specialized hardware while maintaining full adaptability to different production requirements.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10990086B2Module for a technical facility and method for controlling a technical facility

Publication Date: 2021.04.27 WAGO VERW GMBH

AI summary

The invention relates to a module for a technical facility comprising a technical hardware for executing a technical sub-process, a controller for locally controlling the technical hardware wherein the controller is configured to control the technical hardware automatically and an external interface of the controller, wherein the external interface comprises an OPC-UA server. The OPC-UA server has a fixedly predetermined information structure having static information and dynamic information wherein the static information describes the technical hardware and the controller, and the controller writes the dynamic information as real-time values of the technical hardware into the information structure. Furthermore, a corresponding method for controlling a technical facility is claimed.