Runtime Workflow Adaptation for Flexible Factory Automation

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Solution Overview

Problem

Conventional automation systems face challenges in dynamic adaptability and flexibility, particularly in smart factory contexts where production requirements change frequently, due to the need for extensive re-programming and testing, which is resource-intensive and time-consuming, and limits their ability to handle small lot sizes and varied products.

Innovation Solution

The implementation of a method and system that allows for dynamic adaptation of workflows in automation systems by using collaborating machines with local workflow execution contexts, shared databases, and distributed ledgers to coordinate automated handling functions, enabling real-time configuration and optimization of production processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional automation systems are used with fixed preprogrammed workflows, then system reliability is maintained, but adaptability to changing production requirements deteriorates

Engineering Contradiction:

Improveadaptability to changing production requirementsVSAvoidcomplexity of re-programming and testing

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements dynamic workflow adaptation by allowing workflow definitions to be modified at runtime without system reprogramming. The workflow manager enables dynamic creation, modification, and deletion of workflow definitions based on changing production requirements, transforming the static automation system into a dynamic one that can adapt to new scenarios.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent segments the automation system into independent components: workflow definitions, workflow instances, and workflow manager. This segmentation allows individual workflow definitions to be modified without affecting the entire system, enabling targeted updates and reducing the complexity of system-wide re-programming and testing.

Inventive Principle:

Principle #1Segmentation

2Productivity

If workflow definitions are modified at runtime, then productivity is improved through faster response to changes, but system reliability deteriorates due to potential errors in dynamic modifications

Engineering Contradiction:

Improveresponse speed to production changesVSAvoidsystem stability during dynamic modifications

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs preliminary validation and compilation of workflow definitions before they are activated. The workflow manager validates and compiles workflow definitions upon creation or modification, ensuring they meet system requirements before execution. This preliminary action prevents erroneous workflows from compromising system reliability while maintaining runtime adaptability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback mechanisms through workflow instance tracking and status monitoring. The workflow manager continuously monitors workflow execution and provides feedback on system state, enabling detection and correction of potential errors during dynamic modifications, thus maintaining reliability while allowing productivity improvements.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If extensive re-programming and testing is performed for each change, then manufacturing precision is maintained, but loss of time increases significantly

Engineering Contradiction:

Improveprecision of production processVSAvoidtime for re-programming and testing

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent enables dynamic workflow definition modification without requiring system reprogramming. Workflow definitions can be created, modified, or deleted at runtime through the workflow manager, eliminating the time-consuming re-programming phase while maintaining precision through validation mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system performs preliminary validation and compilation of workflow definitions before activation. This ensures that precision requirements are met through automated checking of workflow logic and constraints, replacing manual testing while maintaining manufacturing precision and significantly reducing the time required for changes.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If standardized collaboration protocols are used between machines, then ease of operation is improved, but adaptability to varied hardware and software deteriorates

Engineering Contradiction:

Improvecompatibility with varied hardware and softwareVSAvoidcomplexity of coordination between machines

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a universal workflow definition format that can represent diverse automated handling functions across different hardware and software platforms. The workflow manager provides a unified interface for managing workflows regardless of the underlying machine diversity, enabling adaptable integration without increasing coordination complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11221852B2Method for dynamic adaptation of a workflow of an automatic system

Publication Date: 2022.01.11 SIEMENS AG

AI summary

Provided is a method for dynamic adaption of a workflow, WF, of an automation system, AS, wherein the workflow, WF, includes automated handling functions, AHFs, implementing associated production steps of a production process controlled by a workflow processor, WP, of a machine of the automation system and at least one automated handling function, AHF, shell configured to plug a pluggable automated handling function, pAHF, into the workflow, WF, of the automation system during runtime of the automation system for adaption of the workflow, WF.