Plant Control Programming Using Reusable Component Templates
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Solution Overview
Problem
Complex plant control systems face difficulties in programming due to the large number of components and data connections, leading to increased complexity and error-prone manual data linking, which impairs testability and maintainability.
Innovation Solution
Abstracting functions and connections into reusable descriptions stored in component templates, allowing for automated generation of program code that maps complex functionalities across control units, enabling efficient data exchange and reduced maintenance efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual data linking between components is performed, then complete data connections can be established, but programming complexity and error probability increase significantly
Solution Approach 1:
The system segments the plant control system into reusable component templates with predefined interface descriptions. Each template encapsulates specific functionality (e.g., motors, drives, axes) with standardized data exchange interfaces, allowing complex systems to be built from modular units rather than manual point-to-point connections.
Solution Approach 2:
Component templates serve as reusable copies that can be instantiated multiple times throughout the plant description. Once a component template with its interface descriptions is created, it can be copied and referenced repeatedly, eliminating the need to manually recreate similar data connection structures for each component instance.
2Productivity
If component templates with interface descriptions are used, then programming time is reduced and automation is enabled, but initial system setup complexity increases
Solution Approach 1:
Interface descriptions and component templates are prepared in advance before actual plant programming begins. The standardized interface descriptions define data exchange requirements beforehand, allowing components to be quickly assembled and connected without ad-hoc programming during system implementation.
Solution Approach 2:
The interface descriptions are designed to be universal and applicable across multiple component types and scenarios. A single interface description structure can accommodate various data exchange patterns (reading, writing, monitoring) across different components, reducing the need for component-specific programming logic.
3Ease of repair
If standardized component templates are implemented, then system maintainability improves, but flexibility in handling unique component variations decreases
Solution Approach 1:
While maintaining standardized interface descriptions for consistency, the system allows local customization of component-specific parameters and properties. Each component instance can have unique configuration values (e.g., specific motor parameters, axis limits) while still adhering to the standardized interface structure, enabling both maintainability and flexibility.
Data Source
AI summary
In a method for programming a plant control system having a plurality of control units (6) connected to one another and to sensors and/or actuators, a plurality of component templates (2) of plant parts are called up from a component template memory (1), and components (4) are created from these templates and are linked to one another in a plant description (3). For each component (4) of the plant description (3), a component program code is transmitted to an allocated control unit (6). The method makes it possible to start up a plant control system easily and time-efficiently with minimal testing and maintenance effort, even in the case of complex plants.