Module Control Logic Inference for Industrial Plant Retrofit
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Solution Overview
Problem
There is a need for a method to reverse engineer the control logic of modules in modular industrial plants, especially for older or third-party modules where the control system description is not present, to facilitate control system replacement and understand the behavior of Process Equipment Assemblies (PEAs) in industrial processes.
Innovation Solution
A computer-implemented method that infers equipment state transition conditions from module-related data, including runtime data and rule-based algorithms, to reverse engineer the control logic of modules, enabling the creation of necessary engineering information for control system replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If control system replacement is performed on older or third-party modules without existing control system descriptions, then control system modernization and interoperability are improved, but the complexity of reverse engineering control logic and the time required for engineering increase
Solution Approach 1:
The system uses runtime data as feedback to infer control logic. By continuously monitoring equipment states and transitions during module operation, the reverse engineering process automatically learns and reconstructs the control logic without requiring prior documentation, thus reducing the complexity of reverse engineering while improving interoperability
Solution Approach 2:
The module performs self-description by automatically generating control logic information from its own runtime data. The system enables itself to be reverse engineered through automated inference algorithms that analyze equipment state transitions and generate control logic representations, eliminating the need for manual reverse engineering and reducing engineering complexity
2Ease of manufacture
If manual reverse engineering methods are used to understand control logic of old PEAs, then control system replacement can be achieved, but the time and material efforts required increase significantly
Solution Approach 1:
The patent replaces manual reverse engineering processes with automated computational methods. Instead of manual analysis of control logic, the system uses automated inference algorithms that process runtime data and generate control logic representations, dramatically reducing the time and material efforts required for control system replacement
Solution Approach 2:
The system changes the parameters of the reverse engineering process by using runtime operational data as the input basis instead of requiring manual documentation. By inferring control logic from actual equipment state transitions during operation, the system automates the process and reduces the time and resources needed for control system replacement
Data Source
AI summary
A computer-implemented method for reverse engineering control logic of a module for a modular industrial plant includes: obtaining module-related data including runtime data relating to prior use of the module during a timeperiod in which at least one piece of equipment of the module transitions from a first equipment state to a second equipment state, the runtime data including tags indicating the equipment state of the equipment at a plurality of timepoints during the timeperiod; and inferring from the module-related data one or more equipment state transition conditions causing the equipment to transition from the first equipment state to the second equipment state.