Modular Process Control System for Non-Linear Modeling
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Solution Overview
Problem
Conventional process control systems face challenges in flexibility and efficient development, particularly in managing non-linear processes, due to the need for close coordination between database, runtime, and system software, which limits the reuse of models and increases development time and costs.
Innovation Solution
A method and system that includes a modeling module, a computational module, and a user interface module, coordinated by a coordination module, allowing for the development and implementation of control over non-linear processes using linear, piecewise, or non-linear models, enabling interchangeable platforms and decentralized architecture for component reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional process control systems use integrated software architecture with close coordination between database, runtime, and system software, then system reliability is improved, but device complexity and development time increase
Solution Approach 1:
The patent divides the process control system into separate functional modules: process control module, optimization module, and execution module. Each module operates independently with defined interfaces, eliminating the need for close coordination between database, runtime, and system software while maintaining system reliability through modular architecture.
Solution Approach 2:
The patent introduces a process control module as an intermediary layer between the optimization module and execution module. This mediator handles communication and data exchange, reducing direct coordination requirements between other components and simplifying the overall system architecture.
2Manufacturing precision
If process control software is highly customized to particular processes, then manufacturing precision is improved, but adaptability decreases and development costs increase
Solution Approach 1:
The patent creates a universal optimization module that can be applied across different process control scenarios. The module uses standardized inputs and outputs, allowing the same optimization algorithm to be reused for various processes without custom development, thereby improving adaptability while maintaining precision through parameter adjustment.
Solution Approach 2:
The patent enables customization through parameter adjustment rather than code modification. The optimization module accepts process-specific parameters as inputs and adapts its behavior accordingly, allowing the same software to achieve manufacturing precision for different processes by simply changing parameters rather than rewriting code.
3Manufacturing precision
If controllers use model-based control techniques to control industrial equipment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent separates the complex model-based control functionality into a dedicated optimization module that is distinct from the basic process control module. This segmentation allows the complex optimization algorithms to be isolated and managed separately, reducing the apparent complexity in the overall control system while maintaining high manufacturing precision.
Solution Approach 2:
The process control module serves as an intermediary that simplifies the interface between the optimization module and the industrial equipment. It handles the complex model-based control calculations in the optimization module and presents simplified control commands to the equipment, reducing the perceived complexity in the control system architecture.
4Reliability
If process control systems require close coordination between software components during development, then system reliability is improved, but productivity decreases
Solution Approach 1:
The patent divides the software into independent modules with well-defined interfaces, allowing each module to be developed, tested, and deployed separately. This eliminates the need for close coordination between all software components during development, significantly improving development productivity while maintaining integration reliability through standardized interface contracts.
Solution Approach 2:
The patent creates universal communication protocols and data structures that work across all modules. This universality allows different teams to develop modules independently using the same standards, improving development speed while ensuring reliable integration through consistent interface definitions.
Data Source
AI summary
A method and system for process control. The control system can be operably coupled to a processing system. The control system can include control devices operably coupled to the processing system; a modeling module to provide a linear model based at least in part on the processing system; a computational module to provide controller algorithms associated with the control devices; a user interface module to present at a user interface controller information based at least in part on the linear model and the controller algorithms; and a separate coordination module for establishing communication between the modeling module, the computational module and the user interface module. One or more control signals can be provided to at least one of the control devices for controlling the processing system. In one embodiment, the modeling module can generate the linear model from a non-linear process.