Phase Function Blocks for Configurable Process Automation
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Solution Overview
Problem
Conventional automation solutions for process control systems in processing facilities, such as chemical, pharmaceutical, and petrochemical plants, fail to meet aggressive real-time requirements, necessitating a more flexible and efficient automation approach.
Innovation Solution
The implementation of a phase function block apparatus and method within a process control system that allows for configurable automation by providing parameters to control modules, managing resource acquisition and release, and monitoring execution status across multiple controllers, enabling modular and robust process automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional automation solutions using supervisory personal computer technology are used, then the system is easier to implement, but the real-time execution capability and speed are insufficient
Solution Approach 1:
The automation system is segmented into multiple functional modules including phase function blocks, recipe control modules, and sequential control modules. Each module handles specific tasks independently, enabling parallel execution and improving real-time performance without requiring a complete system redesign.
Solution Approach 2:
The system implements dynamic module acquisition and release mechanisms where modules are activated only when needed and deactivated when not in use. This dynamic allocation optimizes resource utilization and enables flexible real-time execution while maintaining system simplicity.
2Reliability
If flexible and configurable automation is implemented to meet aggressive real-time requirements, then the real-time execution capability improves, but the system complexity increases
Solution Approach 1:
The phase function blocks and control modules are designed as universal, multi-functional components that can be configured for different process control tasks through parameter settings rather than structural changes. This allows the same hardware platform to reliably meet various real-time requirements across different applications.
Solution Approach 2:
The system achieves flexibility and reliability through parameter-based configuration of module behavior, execution priorities, and timing characteristics. By changing parameters rather than system architecture, the system can adapt to different real-time requirements while maintaining a consistent, manageable structure.
3Adaptability or versatility
If modular control modules are used to provide flexible process automation, then the adaptability improves, but the system integration and coordination complexity increases
Solution Approach 1:
The patent introduces intermediary components including phase function blocks that act as mediators between recipe control modules and sequential control modules. These intermediaries standardize communication interfaces and coordination protocols, enabling flexible module integration while reducing the complexity of system-wide coordination.
Solution Approach 2:
The control architecture implements a nested structure where phase function blocks contain references to sequential control modules, which in turn contain references to individual control modules. This hierarchical nesting organizes the complex system into manageable layers, improving adaptability while reducing integration complexity through structured composition.
Data Source
AI summary
Phase function blocks are associated with a process for producing at least one product or part thereof. For example, a phase function block could reside in a recipe control module defining the process. Each phase function block can be executed to implement the process. A phase function block may acquire and initiate execution of a module providing control over a process element. The phase function block may also provide one or more first parameters to the module. The first parameters define how the module implements a portion of the process using the process element. In addition, the phase function block may retrieve one or more second parameters from the module. The second parameters are associated with results of the execution of the module. Multiple phase function blocks could be contained in multiple recipe control modules, which are distributed in multiple controllers in a hard real-time process control system.