Modular Plant Logic Engineering With Extender Units for Complex Recipes
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Solution Overview
Problem
Current methods for engineering industrial modular plants limit integration depth and fidelity of process models, failing to consider properties like pipe lengths or diameters, and are not user-friendly for complex process recipes, defeating the purpose of simplicity and speed in modular automation.
Innovation Solution
A method for custom logic engineering in industrial modular plants involves selecting module type packages and extender units based on process data to create a custom process topology, extending the control scheme to represent dynamic behavior, allowing for complex orchestration schemes without control code programming, using a modular engineering tool to model and control production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard modular type packages (MTPs) are used to represent process modules, then engineering simplicity and speed are maintained, but integration depth and fidelity of process models are limited (cannot consider pipe lengths, diameters, or perform unit conversions)
Solution Approach 1:
The system segments the process representation into two distinct layers: MTPs for physical process modules and extender units for logical functions. This segmentation allows each layer to specialize - MTPs maintain simplicity while extender units provide the additional fidelity needed for complex process modeling, including pipe properties and unit conversions.
Solution Approach 2:
Extender units act as intermediaries between MTPs, enabling complex logical functions and process data representations without requiring changes to the core MTP structure. These extender units serve as mediators that connect physical modules while adding the necessary process-specific details like pipe lengths, diameters, and conversion capabilities.
2Adaptability or versatility
If full-fledged IEC 61131 programming is used to design the process orchestration layer, then complex process recipes can be implemented, but the purpose of simplicity and speed in modular automation is defeated
Solution Approach 1:
The system dynamically adapts the control scheme complexity based on process requirements. For simple processes, standard MTP connections suffice. For complex recipes, extender units are dynamically added to provide the necessary logical functions, allowing the system to scale from simple to complex without always requiring full programming capability.
Solution Approach 2:
Instead of requiring full IEC 61131 programming capability for all cases, the system applies partial action by using extender units only where needed for complex logical functions. This partial approach provides sufficient versatility for complex recipes while avoiding the excessive complexity of full programming in simpler cases.
3Manufacturing precision
If extender units are added to represent additional process data and logical functions, then process model fidelity and complexity handling are improved, but system complexity increases
Solution Approach 1:
Extender units are designed as universal components that can be applied to multiple different MTP combinations and process scenarios. This multi-functionality allows a single extender unit type to serve various purposes, reducing the overall number of different components needed and managing system complexity through reuse rather than proliferation of specialized elements.
Data Source
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AI summary
The present invention is concerned with a method for custom logic engineering in an industrial modular plant executing a production process, comprising the steps: receiving (S10) process data for the production process using at least one physical process module; determining (S20) a custom process topology (10), by - selecting (S21), based on the received process data, at least one module type package, MTP, (11, 12, 13) correlating to the at least one respective physical process module from a database, wherein the module type package (11, 12, 13) is a digital representation of the respective physical process module; - selecting (S22) at least one extender unit (20, 30, 40) from the database based on the received process data, representing a logical function of the production process; - determining (S23) connections (CL, CF) between the at least one extender unit (20, 30, 40) and the at least one MTP (11, 12, 13); - setting (S24) properties of the at least one extender unit (20, 30, 40) based on the received process data; determining (S30) an extended control scheme for controlling dynamic behaviour of the production process using the determined custom process topology (10).