Autonomous OPC-UA Module Control for Flexible Production Integration
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Solution Overview
Problem
Conventional production facilities struggle with fluctuating product demands due to insufficient modular control integration, leading to inefficiencies and complex reconfiguration processes, especially in industries like chemistry and food production.
Innovation Solution
A modular technical facility with autonomous controllers and a server-based external interface that provides static and dynamic information, allowing for easy integration and communication of modules, minimizing control effort and facilitating PFE engineering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production facilities are optimized for a certain production rate, then production efficiency is improved, but flexibility to handle fluctuating product quantities deteriorates
Solution Approach 1:
The facility is divided into independent, modular units that can be individually controlled and scaled. Each module can operate autonomously or be coordinated with others, allowing the system to flexibly adjust production capacity by activating or deactivating specific modules based on demand fluctuations.
Solution Approach 2:
The control system dynamically adjusts the operational state of modules based on real-time production requirements. Modules can be quickly brought online or taken offline, and their operational parameters can be dynamically modified to match changing product quantity demands without reconfiguring the entire facility.
2Adaptability or versatility
If facility control is reconfigured or reprogrammed when adding or modifying systems, then system functionality is improved, but time and complexity increase
Solution Approach 1:
The control system uses universal, standardized communication interfaces and protocols that work across all modules regardless of their specific function. This allows new modules to be integrated without custom programming, as they automatically communicate with the central control through standardized commands and data structures.
Solution Approach 2:
Modules are pre-configured with standardized control interfaces and communication protocols during manufacturing. This preliminary setup eliminates the need for time-consuming on-site configuration and programming when modules are added or modified, as they can be seamlessly integrated into the existing system with minimal setup.
3Reliability
If control hardware is outdated or insufficiently documented, then existing system operation is maintained, but integration of new hardware deteriorates
Solution Approach 1:
A standardized communication interface acts as an intermediary layer between the central control system and individual modules. This interface layer abstracts the complexity of specific hardware implementations, allowing new modules with different hardware configurations to be integrated without modifying existing control logic, while maintaining reliable communication through standardized protocols.
4Ease of manufacture
If modular facility concepts are implemented, then ease of expansion is improved, but control integration complexity deteriorates
Solution Approach 1:
All modules use homogeneous, standardized control interfaces and communication protocols, ensuring uniformity across the modular system. This homogeneity allows modules to be freely combined and expanded without increasing control integration complexity, as each module interacts with the central control in the same standardized manner regardless of its specific function or position in the system.
Data Source
AI summary
A module for a technical facility includes a technical hardware for executing a technical sub-process, a controller for locally controlling the technical hardware wherein the controller is configured to control the technical hardware autonomously and an external interface of the controller, wherein the external interface comprises an OPC-UA server. The OPC-UA server has a fixedly predetermined information structure having static information and dynamic information wherein the static information describes the technical hardware and the controller, and the controller writes the dynamic information as real-time values of the technical hardware into the information structure.