Modular Plant Orchestration Layer for Recipe-Free Module Exchange
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Solution Overview
Problem
The orchestration of modular industrial plants often results in suboptimal module selection due to engineer knowledge limitations, leading to bottlenecks that require time-consuming recipe adaptations when replacing modules with different interfaces.
Innovation Solution
The introduction of a process orchestration layer controlling combined modules, which comprise multiple modules and functional blocks, allowing for indirect control and enabling flexible module exchange without adapting recipes, by utilizing existing function block types and supporting material and signal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modules are selected based on engineer's knowledge without a module pool, then module selection flexibility is maintained, but suboptimal module selection occurs leading to bottlenecks
Solution Approach 1:
The patent creates a universal module pool where modules are standardized with defined interfaces and capabilities. This allows any module to be used in multiple different plant configurations and processes, enabling both flexible selection and optimal performance. The standardized interfaces ensure that modules can be exchanged without causing bottlenecks, as they all conform to the same communication and operational standards.
Solution Approach 2:
The module pool is pre-configured with modules that have been validated for specific functions and interfaces. By preparing modules in advance with standardized characteristics, the system eliminates the need for time-consuming adaptations when modules need to be exchanged or upgraded, thus preventing bottlenecks before they occur.
2Productivity
If a module producing a bottleneck is exchanged by another more capable module, then process capability is improved, but recipe adaptation time and effort increase considerably
Solution Approach 1:
Modules in the pool are designed with universal interfaces and standardized functionality. When a module is exchanged for a more capable version, the standardized interface ensures compatibility with existing recipes and control systems. This eliminates the need for time-consuming recipe adaptations, as the new module can operate with the same control parameters and interfaces as the original module.
Solution Approach 2:
The patent uses virtual representations of modules with standardized interface definitions. When exchanging physical modules, the virtual model remains the same, allowing recipes to reference the standardized interface rather than module-specific details. This copying approach enables module exchange without recipe modification.
3Adaptability or versatility
If modules with different interfaces are used to solve bottlenecks, then module capability is enhanced, but interface compatibility problems arise requiring recipe adaptations
Solution Approach 1:
The module pool establishes universal interface standards that all modules must conform to. This allows modules with different internal capabilities and implementations to communicate through a standardized interface. The universality principle ensures that enhanced module capabilities do not create interface compatibility problems, as all modules speak the same interface language defined in the pool.
Data Source
AI summary
An engineering system for orchestration of an industrial plant includes: a modular plant to be orchestrated including at least one processor from a topology having: a process orchestration layer, and a plurality of modules. A portion of the plurality of modules are formed as at least one combined module. Each combined module of the at least one combined module has at least two different modules of the portion of the plurality of modules. The process orchestration layer controls the plurality of modules. The control by the process orchestration layer includes in-direct control of the portion of the plurality of modules via control of the at least one combined module.