Modular Plant Integration Using OPC UA and Distributed Control
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Solution Overview
Problem
Current process systems with central control technologies face challenges in flexibility and efficiency, particularly in handling low lot sizes and varying production conditions, as they require a central control system that is slow to adapt and lacks decentralized communication between self-sufficient modules.
Innovation Solution
A modular system where each plant module is equipped with control technology and connected via OPC UA communication, with a central server storing configuration data and providing access paths for each module to connect and communicate, allowing for decentralized and distributed control without a central DCS system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a central control system is used to control all process units, then centralized control and coordination are achieved, but flexibility and adaptability to changing production conditions deteriorate
Solution Approach 1:
The patent divides the centralized control system into multiple autonomous control units, each capable of independent decision-making. Each control unit manages its own process unit and can autonomously adapt to production changes, eliminating the need for a single centralized controller and thereby improving flexibility while reducing overall system complexity.
Solution Approach 2:
The control architecture transitions from a static centralized structure to a dynamic distributed network where control units can be added, removed, or reconfigured based on production needs. This dynamic reconfigurability allows the system to adapt flexibly to changing conditions without requiring complete system redesign.
2Productivity
If modules are made autonomous with local control, then flexibility and response time improve, but communication infrastructure and integration complexity increase
Solution Approach 1:
The patent implements a universal communication protocol that enables all autonomous control units to interact through standardized interfaces. This multi-functional communication infrastructure supports various data exchange patterns (control signals, status reports, alarm notifications) through a single standardized system, reducing overall complexity despite the distributed architecture.
Solution Approach 2:
The communication infrastructure acts as an intermediary layer that facilitates coordinated interaction between autonomous units without requiring direct complex point-to-point connections. This mediator approach simplifies integration by providing standardized message routing and data exchange mechanisms.
3Loss of time
If engineering and configuration are centralized, then system consistency is maintained, but engineering time and configuration complexity increase
Solution Approach 1:
The patent employs pre-configured module templates with standardized interfaces and behaviors that can be quickly instantiated and deployed. Rather than configuring each module from scratch, engineers can select from pre-defined templates and make minimal customizations, dramatically reducing engineering time while maintaining system consistency through standardized designs.
Solution Approach 2:
The system uses configuration templates and reusable module definitions that can be copied and adapted across multiple instances. This copying approach ensures consistency across the distributed system while eliminating repetitive configuration work, as proven configurations can be replicated and modified as needed.
Data Source
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AI summary
The invention relates to the integration of a plurality of installation modules each having at least one process-technical unit which, besides hardware, also conceals 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 communications 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 models 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 communications 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 respective function thereof to the outside fire data points and services.