Process Automation Configuration via P&ID Diagrams
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Solution Overview
Problem
Current automation system configuration methods using IEC 61131-3 languages are inadequate for complex, object-oriented systems, leading to increased complexity and error-prone control logic generation, which can result in malfunctioning automation systems.
Innovation Solution
A configuration system that utilizes structural process diagrams with interface components to generate process object instances, perform discovery, querying, selection, and connection actions, and compute aggregate states for control logic generation, while also providing a cause-and-effect matrix for visualization and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional IEC 61131-3 languages are used for configuration, then compatibility with existing control systems is maintained, but configuration complexity increases and error probability rises for object-oriented systems
Solution Approach 1:
The patent uses P&ID diagrams as a template or copy of the physical process structure to automatically generate control logic. By copying the structural relationships from the P&ID diagram, the system derives control logic without manual programming, reducing errors and complexity while maintaining reliability
Solution Approach 2:
The patent replaces manual mechanical configuration methods (traditional IEC 61131-3 programming) with an automated computational system. The processor automatically generates control logic by analyzing P&ID diagrams, substituting human-driven configuration with algorithm-driven automation to reduce errors and complexity
2Productivity
If manual control logic generation is performed using traditional methods, then flexibility in customization is maintained, but time consumption and error probability increase
Solution Approach 1:
The P&ID diagram serves as preliminary documentation that contains all structural information needed for control logic generation. By preparing this diagram in advance with proper symbols and interconnections, the system can automatically generate control logic without time-consuming manual programming, significantly reducing configuration time
Solution Approach 2:
The system performs self-service by automatically generating control logic from the P&ID diagram without requiring manual intervention for logic creation. The processor autonomously analyzes the diagram structure and produces control logic, eliminating the time-consuming manual configuration process while maintaining accuracy
3Loss of information
If comprehensive interface connections are established between process objects, then system integration and monitoring capability improve, but system complexity increases
Solution Approach 1:
The P&ID diagram serves multiple functions simultaneously: it represents the physical process structure, defines process objects, establishes interconnections, and enables control logic generation. This multi-functionality reduces the need for separate configuration activities and simplifies system integration while maintaining comprehensive status visibility
Solution Approach 2:
The P&ID diagram acts as an intermediary that bridges the physical process and the control system. By using this intermediate representation, the system can automatically derive control logic and establish connections without complex direct integration, reducing integration complexity while maintaining full system visibility
Data Source
AI summary
A configuration system and method for process automation configured to access structural process diagrams representing process components. Each process component includes interconnections between process components. Each interconnection represents a physical connection. The system has at least one processor configured to generate corresponding process object instances for process components wherein a particular component type defines at least an interlock property and/or an operating condition.