Modular Process Control for Fast Reconfiguration in Production
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Solution Overview
Problem
Conventional process engineering systems are not designed to handle fluctuating product quantities and short product life cycles, leading to inefficiencies and high costs due to the need for frequent reconfiguration and reprogramming of system controllers.
Innovation Solution
A modular process engineering system where each module has independent local control and an external interface that receives defined commands to transition between specific states, allowing for decentralized and automatic control, reducing the need for extensive reconfiguration and reprogramming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production systems are designed for continuous operation optimized for a certain quantity of product per time unit, then production efficiency is improved for that specific quantity, but the system cannot handle fluctuating product quantities and requires expensive reconfiguration when adding or converting system components
Solution Approach 1:
The system is divided into independent modules, each with its own controller that can operate autonomously. This segmentation allows individual modules to be added, removed, or reconfigured without affecting the entire system, enabling flexible adaptation to fluctuating production requirements while maintaining efficient operation of active modules
Solution Approach 2:
The system implements dynamic reconfigurability where modules can be dynamically added or removed from production lines. The control system automatically adapts to changing module configurations, allowing the production system to dynamically adjust capacity and mix according to fluctuating product quantity demands
2Adaptability or versatility
If the system is reconfigured or reprogrammed to add or convert components, then the system can adapt to new requirements, but the reconfiguration process is expensive and time-consuming, taking time comparable to hardware conversion
Solution Approach 1:
Each module is pre-configured with its own controller and control logic before being integrated into the system. This preliminary configuration eliminates the need for time-consuming on-site reprogramming when modules are added or reconfigured, as modules can be independently prepared and then seamlessly integrated into the production system
Solution Approach 2:
Modules are self-contained with integrated controllers that manage their own operations independently. This self-service capability allows modules to be added or reconfigured without requiring extensive external reprogramming, as each module autonomously manages its control logic and can be independently configured
3Ease of manufacture
If existing control hardware is used, then cost is reduced, but outdated control hardware may not provide all requisite functions for new hardware and inadequate documentation makes reconfiguration difficult
Solution Approach 1:
The system uses standardized control interfaces and communication protocols that are universally compatible across different module types and generations. This universality allows existing control hardware to work with new modules and functions without requiring specialized reconfiguration, maintaining cost-effectiveness while enabling access to new capabilities
Data Source
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.