Modular Plant Topology Optimization for Higher Module Utilization
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Solution Overview
Problem
Existing methods for reconfiguring modular industrial plants to quickly adapt to different production processes are inefficient and costly, as they often rely on sub-optimal human engineering and lack a systematic approach to optimize resource utilization.
Innovation Solution
A computer-implemented method that optimizes the topology of modular industrial plants by replacing process modules with candidates from a pool that offer higher theoretical utilization, using a theoretical utilization metric and key performance indicators to guide the optimization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human-engineered topology is used for modular plant configuration, then the plant can be assembled and reconfigured, but the resource utilization is sub-optimal and costs are high
Solution Approach 1:
The patent applies parameter changes by computing a theoretical utilization metric for each process module based on recipe requirements and module capabilities. The optimization algorithm changes the topology configuration parameters by replacing modules with candidates that have higher theoretical utilization, thereby improving resource utilization while maintaining reconfiguration capability
Solution Approach 2:
The patent substitutes manual human engineering with an automated computer-implemented optimization method. The system automatically computes theoretical utilization, identifies candidate modules, and generates optimized topologies without relying on human expertise, thereby eliminating the sub-optimality inherent in manual configuration
2Reliability
If more process modules are used to ensure process execution, then the plant can handle various production processes, but the cost and complexity increase
Solution Approach 1:
The patent promotes universality by selecting process modules that can perform multiple functions within the same topology. The optimization algorithm identifies modules with higher theoretical utilization, meaning they can handle multiple recipe steps or process operations, thereby reducing the total number of modules needed while maintaining process execution capability
Solution Approach 2:
The patent applies merging by consolidating multiple process functions into fewer highly-utilized modules. The optimization process replaces multiple lower-utilization modules with fewer higher-utilization modules that can perform combined functions, reducing overall system complexity
3Ease of operation
If manual topology optimization is performed, then engineering flexibility is maintained, but time and human resources are consumed
Solution Approach 1:
The patent implements self-service by creating an automated system that performs topology optimization without human intervention. The computer-implemented method autonomously computes theoretical utilization, evaluates candidate modules, and generates optimized topologies, eliminating the time-consuming manual engineering process while maintaining flexibility through programmable optimization criteria
Solution Approach 2:
The patent substitutes manual engineering operations with automated computational processes. The optimization algorithm automatically performs tasks that previously required human engineers, including module selection, topology generation, and utilization calculation, thereby eliminating time loss while preserving engineering flexibility through configurable parameters
Data Source
AI summary
A computer-implemented method includes obtaining an amount of a resource and/or capability of a process module, and dividing this amount by the maximum amount of the respective resource and/or capability to obtain a theoretical utilization of the resource and/or capability as the theoretical utilization of the process module. A pool of available process modules is searched to identify candidate process modules to replace the process module. The theoretical utilization for each candidate module is determined and an optimized topology of the plant is generated by replacing the process module with a candidate process module that has a same or a higher theoretical utilization than process module.