Automatic Process Module Configuration via Operational Data
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Solution Overview
Problem
In industrial automation, process modules face complexity in reconfiguration and data management due to the need for rapid switching between products, software updates, and decentralized decision-making, leading to constraints such as data quantity, format incompatibility, and safety concerns when moving between different operational environments.
Innovation Solution
A computer-implemented method and system that automatically configures process modules by collecting and storing operational data across environments, using a memory function to receive and store data, and a reply function to process queries and derive configuration parameters for seamless operation across different operational settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If process modules are manually reconfigured when moved between operational environments, then configuration accuracy can be maintained, but reconfiguration time and operational complexity increase significantly
Solution Approach 1:
The system performs preliminary actions by automatically collecting operational data from the process module in its current environment, storing it in a database, and preparing configuration parameters before the module is moved. When the module is relocated to a new operational environment, the configuration is automatically generated and applied based on the stored data, eliminating manual reconfiguration steps and reducing downtime while maintaining accuracy.
2Stability of the object's composition
If operational data is collected and stored for all process modules, then data consistency across environments is improved, but data management complexity increases
Solution Approach 1:
The system implements a universal database structure and standardized data collection methodology that works across all operational environments and process modules. The database is designed to store operational data in a consistent format regardless of the specific environment, allowing the same data management approach to serve multiple purposes: maintaining data consistency, enabling automatic configuration, and supporting various query types without requiring environment-specific management procedures.
3Adaptability or versatility
If process modules are frequently moved between different operational environments, then production flexibility is improved, but safety risks due to configuration errors increase
Solution Approach 1:
The system implements feedback mechanisms where operational data from the process module is automatically collected and used to generate configuration parameters. The configuration is validated against the stored operational data before being applied, ensuring that the module is correctly adapted to its new environment. This automated feedback loop eliminates manual configuration errors and ensures safe operation across different environments, maintaining reliability while enabling frequent moves.
Data Source
AI summary
A process module is automatically configured for operation in a plant. During the operation of the process module in a first phase in a first operational environment, operational data that is related to the process module is received by a computer data system. In a second phase, when the process module is connected to a second operational environment, operational data is received again. The computer data system has a reply function that receives and processes a query and provides a response. Processing the query includes processing the operational data that was received during the first and second phases. The process module is then configured by using configuration parameters that are derived from the response.