Dynamic Recipe Process Flow Modification in Control Systems

Solution Overview

Problem

Current process control systems lack the ability to easily modify recipe process flows during execution, leading to costly mistakes and inefficiencies due to the need for manual intervention by experienced operators, which is time-consuming and prone to errors.

Innovation Solution

A method and apparatus that allow for dynamic modification of recipe process flows during execution by receiving process flow change information, verifying compliance with predefined rules, and automatically activating or deactivating process steps without violating industry standards, thereby reducing user interaction and minimizing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual modification of recipe process flow is performed by experienced operators, then recipe changes can be made during execution, but the process becomes time-consuming and error-prone

Engineering Contradiction:

Improverecipe modifiabilityVSAvoidmodification time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs self-service by automatically verifying process flow changes against predefined rules without requiring manual operator intervention. The rule verification system autonomously checks whether proposed modifications violate process flow rules, eliminating the need for experienced operators to manually verify changes while maintaining compliance.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the mechanical manual process of operator verification with an automated computer-based rule verification system. Instead of operators manually checking modifications against process flow rules, the system automatically retrieves rules from a database and verifies compliance, substituting human cognitive processes with automated computational processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual modification of recipe process flow is performed by experienced operators, then recipe changes can be made during execution, but the complexity of the operation increases due to expertise requirements

Engineering Contradiction:

Improverecipe modifiabilityVSAvoidoperational complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system performs self-service by automatically verifying process flow changes against predefined rules without requiring manual operator intervention. The rule verification system autonomously checks whether proposed modifications violate process flow rules, eliminating the need for experienced operators to manually verify changes while maintaining compliance.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the mechanical manual process of operator verification with an automated computer-based rule verification system. Instead of operators manually checking modifications against process flow rules, the system automatically retrieves rules from a database and verifies compliance, substituting human cognitive processes with automated computational processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If recipe execution continues without interruption to allow modifications, then productivity is maintained, but the risk of errors and violations of process flow rules increases

Engineering Contradiction:

Improveprocess continuityVSAvoidmodification safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary action by retrieving and storing process flow rules in a database before recipe execution begins. This pre-prepared rule set enables rapid automated verification during runtime modifications without interrupting process continuity, as the verification logic is already prepared and can be applied instantaneously to proposed changes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by automatically verifying proposed process flow changes against predefined rules and providing immediate verification results. This closed-loop feedback mechanism ensures that modifications are checked for compliance before being applied, maintaining reliability while allowing continuous operation. The system feedbacks verification status to operators, enabling informed decision-making without process interruption.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP2109022B1Methods and apparatus to modify a recipe process flow associated with a process control system during recipe execution

Publication Date: 2013.10.16 FISHER ROSEMOUNT SYST INC

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AI summary

Example methods and apparatus to modify a recipe process flow during recipe execution are disclosed. A disclosed example method involves executing a recipe, and before completion of execution of the recipe, receiving process flow change information indicative of a modification to a process flow of the recipe. Process flow rules are then retrieved from a process flow rules data structure. The recipe process flow is modified based on the process flow change information in response to determining that at least one requested change indicated by the process flow change information does not violate one of the process flow rules.