Modular Process Control with Autonomous State-Based Controllers

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Solution Overview

Problem

Conventional process engineering systems struggle with fluctuating product demands and short product life cycles, leading to inefficiencies and high costs due to reconfiguration and reprogramming requirements, especially in modular systems where control integration is an open question.

Innovation Solution

A module-based process engineering system with independent local controllers and defined external interfaces allows for decentralized control, enabling modules to automatically transition between specific states in response to high-level commands, minimizing control effort and facilitating easy expansion, reduction, or conversion without reprogramming the superordinate controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional production systems are optimized for a certain quantity of product per time unit, then production efficiency is improved, but adaptability to fluctuating product demands deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoidadaptability to fluctuating product demands

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The production system is divided into independent modular units, each with its own controller that can operate autonomously. This segmentation allows individual modules to be configured for specific production tasks while the overall system can be reconfigured by adding or removing modules, thus maintaining high efficiency for each module while providing system-level adaptability to fluctuating demands.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs dynamic reconfiguration capabilities where modules can be added, removed, or repositioned based on current production requirements. The control system dynamically adapts to changes in module configuration and product demand, allowing the system to optimize efficiency for the current production volume while maintaining flexibility for future adjustments.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If modular system concepts are implemented, then ease of manufacture and system expansion are improved, but control integration complexity deteriorates

Engineering Contradiction:

Improveease of module assemblyVSAvoidcontrol integration complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Each modular unit is equipped with its own independent controller that manages its internal operations autonomously. This self-service capability eliminates the need for complex centralized control integration, as each module handles its own control tasks while communicating basic status information to the overall system, thereby simplifying control integration despite modular complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control architecture employs universal communication interfaces and standardized protocols that allow different modular units to integrate seamlessly regardless of their specific functions. This universality in control integration simplifies the assembly process and reduces complexity by providing a consistent method for connecting and coordinating modules across the entire system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If system reconfiguration is performed to meet changing product demands, then adaptability is improved, but loss of time and reprogramming effort deteriorates

Engineering Contradiction:

Improveadaptability to product life cycle changesVSAvoidreconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Modular units are pre-configured with specific functions and controllers during manufacturing, allowing them to be deployed immediately upon assembly into the production system. This preliminary configuration eliminates the need for time-consuming on-site programming and reconfiguration, enabling rapid adaptation to changing product demands through simple physical reassembly rather than software reprogramming.

Inventive Principle:

Principle #10Preliminary action

4Stability of the object's composition

If centralized control is used for the entire system, then coordination is improved, but control effort and system complexity deteriorates

Engineering Contradiction:

Improvesystem coordinationVSAvoidcontrol effort

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Control functionality is segmented and distributed to individual modular units, each with its own controller that autonomously manages its operations. This segmentation maintains system coordination through standardized communication interfaces while dramatically reducing control effort and complexity by eliminating the need for a single centralized controller to manage every detail of the entire system.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250231542A1Module for a process engineering system and method for controlling a process engineering system

Publication Date: 2025.07.17 WAGO VERW GMBH

AI summary

A module for a process engineering system having process engineering hardware for carrying out a process engineering sub-process, a controller for local control of the process engineering hardware, the controller being set up to control the process engineering hardware independently and bring it to a number of specific defined states, and an external interface of the controller, the external interface being able to receive a number of defined commands which correspond to the specific defined states of the process engineering hardware. In addition, a method is claimed for controlling a process engineering system which is made up of a plurality of modules.