Module Run Sequence Manager for Process Control
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Solution Overview
Problem
Process control systems require numerous modules for varying conditions, leading to inefficient execution and exhaustive validation procedures, as they typically execute all function blocks within a module regardless of necessity, resulting in increased development and validation burdens.
Innovation Solution
Implementing module run sequences that allow the conditional execution of a subset of function blocks based on specific triggers or schedules, enabling only necessary blocks to execute, thereby reducing the number of modules needed and streamlining validation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all function blocks within a module are executed regardless of necessity, then the module execution is simple and consistent, but execution efficiency decreases and validation burden increases
Solution Approach 1:
The patent segments the module execution into multiple run sequences, where each sequence executes only the necessary subset of function blocks for a specific control objective. This allows the system to divide the monolithic module execution into smaller, targeted execution paths, improving efficiency by avoiding unnecessary function block execution while maintaining manageable complexity through structured segmentation.
Solution Approach 2:
The patent implements dynamic module execution by allowing the controller to select different run sequences based on current process conditions and control objectives. Instead of a fixed execution pattern, the system dynamically determines which function blocks to execute by matching trigger conditions with appropriate run sequences, thereby optimizing execution efficiency for varying operational scenarios.
2Adaptability or versatility
If numerous additional modules are created to satisfy different process control routine objectives, then each product requirement is met, but the number of modules increases and validation becomes exhaustive
Solution Approach 1:
The patent makes a single module universal by enabling it to satisfy multiple process control routine objectives through different run sequences. Each run sequence contains a customized subset of function blocks tailored to specific control objectives, allowing one module to replace numerous specialized modules. This multi-functionality approach maintains adaptability to different product requirements while significantly reducing the total number of modules requiring validation.
Solution Approach 2:
The patent merges multiple specialized modules into a single consolidated module that contains all necessary function blocks organized into different run sequences. By combining the functionality of multiple modules into one unified structure with conditional execution paths, the system achieves the same adaptability with fewer modular components, thereby reducing validation scope and complexity.
3Device complexity
If a single module is used for multiple process control objectives, then the number of modules is reduced, but execution efficiency decreases as all function blocks must execute for every objective
Solution Approach 1:
The patent segments the function blocks within the single module into different run sequences, each containing only the subset of function blocks necessary for a specific control objective. This internal segmentation allows the unified module to execute efficiently by activating only the relevant function blocks for the current objective, rather than forcing execution of all function blocks regardless of necessity.
Solution Approach 2:
The patent implements partial action by allowing the module to execute only the necessary portion of function blocks for each control objective through selective run sequence activation. Instead of requiring full execution of all function blocks, the system performs only the partial execution needed to satisfy the current control objective, thereby improving efficiency while maintaining the benefit of using a single unified module.
Data Source
AI summary
Example methods and apparatus to manage module run sequences in a process control environment are disclosed. A disclosed example method includes receiving a module including a plurality of function blocks, receiving an indication of a subset of the plurality of function blocks, and receiving an indication of a first sequence of execution for the subset, wherein the first sequence of execution is different than a second sequence of execution associated with the module. The example method also includes associating the subset with a run sequence identifier, and associating the run sequence identifier with a trigger condition.