Process Controller Dynamic Workflow Adaptation
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Solution Overview
Problem
Existing batch control systems in process control systems struggle to respond effectively to changes in equipment and material status, limiting their ability to execute or invoke other control sequences accordingly.
Innovation Solution
A process controller with memory and processing circuitry that includes procedure modules, a process monitor processor, and a sequence engine processor, enabling the system to receive input signals, apply logic, select and execute supplemental procedures, and update production records based on process changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch control sequences are encoded within the process controller, then the system can execute predefined control tasks, but the system cannot respond dynamically to changes in equipment and material status
Solution Approach 1:
The patent transforms static batch control sequences into dynamic workflows that can adapt during execution. The workflow engine continuously monitors process conditions and dynamically selects and executes supplemental procedures based on current equipment and material status, allowing the control system to respond to changes while maintaining structured execution of control tasks.
Solution Approach 2:
The system implements feedback mechanisms where the workflow engine receives real-time status information from process monitors about equipment and material conditions. This feedback loop enables the system to detect changes during workflow execution and trigger appropriate supplemental procedures, making the control sequence adaptive to actual process conditions.
2Stability of the object's composition
If the control system executes predefined procedures, then operational consistency is maintained, but the system lacks flexibility to invoke additional control sequences based on real-time conditions
Solution Approach 1:
The patent segments the control system into modular components: a workflow engine that manages overall execution, process monitors that detect conditions, and a library of supplemental procedures that can be independently selected and executed. This segmentation allows the system to maintain consistent workflow execution while flexibly integrating additional procedures based on real-time needs.
Solution Approach 2:
The workflow engine serves multiple functions: it executes the primary batch control workflow, monitors process conditions, selects appropriate supplemental procedures, and coordinates their execution. This multi-functional design enables the system to maintain operational consistency while adapting to various process conditions through a single unified control mechanism.
3Device complexity
If batch control sequences follow a fixed execution path, then process control is simplified, but the system cannot adapt to equipment failures or material variations
Solution Approach 1:
The workflow engine acts as an intermediary between the fixed batch control workflow and the variable process conditions. It receives status information from process monitors, evaluates conditions against predefined criteria, and mediates by selecting and triggering appropriate supplemental procedures. This intermediary layer adds adaptability without fundamentally complicating the core batch control structure.
Data Source
AI summary
A process controller a procedure module that includes instructions for executing a procedure, and a plurality of supplemental procedure modules, each of which includes instructions for executing one of a plurality of supplemental procedures. The process controller also includes a process monitor processor configured to receive an input electronic signal indicative of a status of a process feature, apply logic based on the input electronic signal, and generate an output electronic signal in response to the input electronic signal. The process controller also includes a sequence engine processor configured to execute the procedure, receive the output electronic signal, apply logic based on the output electronic signal, select one or more of the plurality of supplemental procedures based on the received output electronic signal, and execute the selected one or more of the plurality of supplemental procedures.