Modular Plant Construction Planning From Process Flow Charts
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Solution Overview
Problem
The existing methods for creating construction plans for modular industrial plants are largely manual and inefficient, requiring significant human intervention and expertise, which hinders quick reconfiguration and optimization of production processes, especially in industries like pharmaceuticals where rapid product evolution and quality improvements are necessary.
Innovation Solution
A method for generating and verifying construction plans for modular plants using flow charts, module descriptions, and computerized processes to automate the selection and interconnection of physical process modules, allowing for faster turnaround times and improved quality without the need for constant automation specialist input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual human engineering is used to create construction plans for modular plants, then expertise and control are maintained, but the process is slow and inefficient
Solution Approach 1:
The system enables automated self-service by using computer algorithms to automatically generate construction plans from process flow charts and module catalogs without requiring manual engineering intervention. The computer selects appropriate modules and determines their interconnections autonomously based on the provided process requirements.
Solution Approach 2:
The patent replaces the mechanical human engineering process with a computer-based automated system. The computer executes algorithms to perform tasks that previously required manual expertise, thereby increasing productivity while reducing dependency on human engineers for routine construction plan creation.
2Loss of time
If manual engineering methods are used, then complex processes can be handled with expertise, but reconfiguration time is excessive
Solution Approach 1:
The system performs preliminary actions by pre-organizing module descriptions in catalogs with their capabilities, inputs, and outputs defined in advance. When reconfiguration is needed, the computer can quickly assemble construction plans by selecting from these pre-characterized modules, dramatically reducing reconfiguration time compared to manual engineering approaches.
Solution Approach 2:
The patent changes the parameters of construction plan creation by transitioning from manual, experience-based methods to automated, algorithm-based methods. This parameter change enables rapid reconfiguration while maintaining ease of manufacture through systematic computerized selection and arrangement of modules based on process requirements.
3Productivity
If automated methods are introduced to speed up construction plan creation, then productivity increases, but verification of feasibility becomes more complex
Solution Approach 1:
The system incorporates feedback mechanisms where the computer automatically verifies construction plans by checking module compatibility, constraint satisfaction, and feasibility criteria. The verification process provides feedback on whether the generated plan meets all requirements, and if not, the system can iteratively adjust the plan until feasibility is achieved.
Solution Approach 2:
The computer system performs multiple functions including construction plan generation, verification, and optimization using the same automated platform. This universal approach handles both creation and verification tasks, managing complexity through integrated automated processes rather than separate manual procedures.
Data Source
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AI summary
A method (100) for generating a construction plan (1a) for a modular plant (1) that is to execute a given industrial process, comprising the following steps: - providing (110) a flow chart (2) of the industrial process, said flow chart (2) comprising a sequence of actions (21-28); - providing (120) at least one catalogue (4) of module descriptions (41-46); - decomposing (130) the flow chart (2) into functional units (31-36) with at least one educt input (I), at least one product output (O) and one or more actions (21-28) leading from the one or more educts to the one or more products; - searching (140) the at least one catalogue (4) for module descriptions (41-46) that match to functional units (31-36); and - for each functional unit (31 -36) for which at least one matching module description (41-46) is found, inserting (150), into the construction plan (1a), the corresponding physical process module (51-56).