Industrial Plant Orchestrator Control for Adaptive Sub-System Targets
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Solution Overview
Problem
Controlling industrial plants is a highly complicated and error-prone task, especially due to the high costs associated with faults, necessitating a higher degree of automation that considers both high-level aspects and component-level operations, which existing technologies have not effectively addressed.
Innovation Solution
A data-driven method using an orchestrator and control agent framework that integrates various control layers and agents, leveraging artificial intelligence models to derive and adjust production targets based on high-level instructions and real-time component data, enabling autonomous operation and reduced operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high degree of automation is implemented to reduce errors and costs, then reliability improves, but device complexity increases
Solution Approach 1:
The control system is divided into multiple hierarchical layers: high-level planning layer, intermediate coordination layer (orchestrator), and low-level execution layer (control agents). Each layer handles specific tasks independently, reducing overall system complexity while maintaining high automation. The orchestrator segments coordination functions from execution functions, allowing manageable complexity at each level.
Solution Approach 2:
The orchestrator acts as an intermediary between high-level production targets and low-level control agents. It translates abstract production goals into specific control instructions, mediating between different control layers and reducing the complexity burden on individual components while maintaining system-wide coordination.
2Adaptability or versatility
If both high-level aspects and component-level operations are considered in control, then adaptability improves, but device complexity increases
Solution Approach 1:
The control system segments adaptability requirements across different layers: the high-level layer handles strategic adaptability to production targets, while the orchestrator handles tactical adaptability to sub-system requirements, and control agents handle operational adaptability to component states. This distributed segmentation enables comprehensive adaptability without concentrating all complexity in one system.
Solution Approach 2:
Each control layer possesses specialized local qualities tailored to its function. The orchestrator has knowledge of sub-system interdependencies and production targets, while control agents have detailed knowledge of their specific components. This local specialization enables adaptability at each level without requiring every component to handle all aspects of control complexity.
3Productivity
If continuous monitoring and updating of production processes is implemented, then productivity improves, but loss of time increases
Solution Approach 1:
The control agents continuously monitor production processes and report status to the orchestrator without interruption. The orchestrator continuously updates production targets based on real-time feedback, ensuring continuous useful action throughout the production process. This continuity maximizes productivity while minimizing idle or non-productive time.
Solution Approach 2:
A closed-loop feedback system is implemented where control agents report production status to the orchestrator, which then updates production targets and sends new instructions. This continuous feedback enables real-time productivity optimization while minimizing time loss through automated rapid response to changing conditions.
Data Source
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AI summary
The invention relates to the field of industrial plants, particularly to a method for controlling a sub-system (200, 300, 400) of an industrial plant (100). The method comprises the steps of: retrieving, by the orchestrator (120), information about the sub-system (200, 300, 400); training the orchestrator (120), based on the retrieved information; receiving, by the orchestrator (120), a high-level production target (180) for the industrial plant (100); deriving, by the orchestrator (120), instructions regarding a production target for the sub-system (200, 300, 400); transmitting, by the orchestrator (120), the instructions to a control agent (220, 320, 420) of the sub-system (200, 300, 400); and starting, by the control agent, a production process, the production process comprising the steps of: reporting, by the control agent, a current state of the components (250, 260, 350, 360, 450, 460), an achievement degree and the alarm-logs (230, 330, 430) of the sub-system (200, 300, 400) to the orchestrator (120); and transmitting, by the orchestrator (120), updated instructions to the control agent (220, 320, 420) of the sub-system (200, 300, 400).