Modular Process Control for Flexible Production Capacity

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Solution Overview

Problem

Conventional process engineering systems are inflexible and inefficient in handling fluctuating product quantities, requiring costly reconfiguration and reprogramming when adapting to changes in production capacity, due to inadequate documentation and outdated control hardware.

Innovation Solution

A modular process engineering system with independently controlled modules that can assume specific defined states, allowing for decentralized and automatic control, minimizing the need for external intervention and enabling easy expansion or reduction of production capacity without extensive reconfiguration of the superordinate control system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional production systems are used, then system stability is maintained, but flexibility in handling fluctuating product quantities deteriorates

Engineering Contradiction:

Improveflexibility in handling fluctuating product quantitiesVSAvoidsystem reconfiguration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The production system is divided into independent, modular units that can be individually controlled and configured. Each module can be independently adapted to different production requirements without affecting the entire system, enabling flexible response to fluctuating product quantities while maintaining overall system stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates dynamically reconfigurable modules that can change their operational parameters and connections based on real-time production demands. This dynamic adaptability allows the system to efficiently handle varying product quantities without requiring complete system reconfiguration.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If system reconfiguration is performed to adapt to changing production capacity, then adaptability improves, but time consumption and cost increase

Engineering Contradiction:

Improveproduction capacity adaptabilityVSAvoidreconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Modules are pre-configured with standardized interfaces and control logic during manufacturing, enabling rapid deployment and integration into the production system. This preliminary preparation significantly reduces the time required for system reconfiguration when production capacity needs to be adjusted.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses universal, standardized module interfaces and control protocols that allow the same modular components to serve multiple functions and be easily reconfigured for different production scenarios, reducing both time and cost of adaptation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If centralized control is used, then system coordination is simplified, but control effort and programming complexity increase

Engineering Contradiction:

Improvesystem coordination simplicityVSAvoidcontrol programming complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Each modular unit is equipped with autonomous control capabilities that enable self-management of local operations. Modules can independently execute their control logic and make local decisions, reducing the programming burden on the centralized system while maintaining coordinated operation through standardized communication interfaces.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

A standardized communication protocol acts as an intermediary between the centralized control system and individual modules. This mediator layer simplifies coordination by providing a uniform interface for command and data exchange, reducing the complexity of direct centralized control programming.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If modular system construction is implemented, then system expansion becomes easier, but integration with control technology becomes more challenging

Engineering Contradiction:

Improvesystem expansion easeVSAvoidcontrol integration complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The modular system employs universal control interfaces and standardized communication protocols that work across all module types. This universality enables easy system expansion while maintaining consistent control integration, as new modules can be integrated using the same standardized methods without requiring custom control solutions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11300935B2Module for a process engineering system and method for controlling a process engineering system

Publication Date: 2022.04.12 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 control system for local control of the process engineering hardware, the control system 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 control system, 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.