Modular Plant Logic Topology 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 require complex programming for high-complexity recipes, defeating the purpose of simplicity and speed in modular automation.
Innovation Solution
A method for custom logic engineering that 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 the integration of logical functions and unit conversions without programming, using a modular engineering tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular type packages (MTPs) are used to represent process modules, then engineering complexity is reduced and automation speed is improved, but integration depth and fidelity of process models are limited, preventing consideration of properties like pipe lengths or diameters
Solution Approach 1:
The patent implements a nested structure where extender units are integrated within the modular type package framework. The extender units nest additional process data representations (like pipe lengths and diameters) within the existing MTP structure, allowing detailed information to be contained within the standardized modular containers without breaking the modular architecture's simplicity and automation capabilities
Solution Approach 2:
The extender units act as intermediaries between the simplified MTP representations and the detailed process data requirements. These intermediary elements enable the transmission and integration of additional properties (pipe lengths, diameters, etc.) without requiring changes to the core MTP structure, thus maintaining automation speed while improving integration depth
2Adaptability or versatility
If full-fledged IEC 61131 programming is used to design the process orchestration layer, then high complexity process recipes can be handled, but the simplicity and speed benefits of modular automation are defeated
Solution Approach 1:
The patent segments the process orchestration functionality by separating standard modular operations (handled by MTPs) from extended logical functions (handled by extender units). This segmentation allows complex recipes to be built by composing simpler modular elements with targeted extensions, avoiding the need for full-fledged programming while maintaining the ability to handle high complexity processes
Solution Approach 2:
The extender units provide dynamic extensibility to the modular system. Rather than requiring static, comprehensive programming for all possible complexities, the system dynamically adapts by allowing selective addition of extender units only where needed, maintaining simplicity for standard operations while enabling complexity handling where required
3Loss of information
If extender units are added to represent additional process data, then integration depth and fidelity are improved, but engineering complexity may increase
Solution Approach 1:
The extender units are designed as universal, standardized elements that can represent multiple types of additional process data (pipe lengths, diameters, various logical functions) through a common interface and structure. This universality allows a single extender unit framework to handle diverse data representation needs without requiring separate engineering approaches for each data type, thus improving process data representation while controlling engineering complexity through standardization
Data Source
AI summary
A method for custom logic engineering in an industrial modular plant executing a production process includes receiving process data for the production process using at least one physical process module; determining a custom process topology by selecting, based on the received process data, at least one module type package, MTP; correlating to the at least one respective physical process module from a database, wherein the module type package is a digital representation of the respective physical process module; selecting at least one extender unit from the database based on the received process data; representing a logical function of the production process; determining connections between the extender unit(s) and the at least one MTP; setting properties of the extender unit(s) based on the received process data; and determining an extended control scheme for controlling dynamic behavior of the production process using the determined custom process topology.