Computerized optimization of an engineered modular plant topology

Patent metadata

Field	Value
Publication number	US-12379715-B2
Application number	US-202217892643-A
Country	US
Kind code	B2
Filing date	Aug 22, 2022
Priority date	Feb 24, 2020
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

A computer-implemented method includes obtaining an amount of a resource and/or capability of a process module, and dividing this amount by the maximum amount of the respective resource and/or capability to obtain a theoretical utilization of the resource and/or capability as the theoretical utilization of the process module. A pool of available process modules is searched to identify candidate process modules to replace the process module. The theoretical utilization for each candidate module is determined and an optimized topology of the plant is generated by replacing the process module with a candidate process module that has a same or a higher theoretical utilization than process module.

First claim

The invention claimed is:

1. A computer-implemented method for optimizing a given topology of a modular plant configured to execute an industrial process according to an engineered recipe, the method comprising:
obtaining, for an original process module in the given topology, an amount of at least one resource and/or capability of the original process module that is utilized when the industrial process is executed according to the engineered recipe, and dividing the amount by a maximum amount of the respective resource and/or capability that the original process module is able to provide, thereby obtaining a theoretical utilization of the resource and/or capability and assigning the theoretical utilization of the resource and/or capability as the theoretical utilization of the original process module;
searching, in a pool of available process modules, for one or more candidate process modules that are able to replace the original process module in the execution of the engineered recipe and fit into the given topology;
obtaining, for each candidate process module, a theoretical utilization of the corresponding resource and/or capability of the respective candidate process module that will ensue when the original process module is replaced by the respective candidate process module;
assigning the theoretical utilization to each candidate process module;
generating an optimized topology of the plant from the given topology by replacing the original process module with a candidate process module that has a same or a higher theoretical utilization than the original process module; and
executing the industrial process by sending commands based on the engineered recipe to process modules of the optimized topology of the plant,
wherein the resource and/or capability comprises a count of services of the original process module and of the one or more candidate process modules, respectively.

2. The method of claim 1 , wherein the given topology and/or the optimized topology comprises:
feeding at least one input of the industrial process as a whole to at least one input port of the original and/or candidate process module;
delivering at least one output of the industrial process as a whole from at least one output port of the original and/or candidate process module; and
providing at least one interconnection between an output port of a first process module and an input port of a second process module.

3. The method of claim 1 , wherein the engineered recipe comprises a temporal sequence of process steps, wherein each step of the temporal sequence of process steps comprises sending at least one command to at least one original and/or candidate process module, and/or performing at least one action by the original and/or candidate process module.

4. The method of claim 3 , wherein at least one transition between successive steps in the engineered recipe comprises waiting for at least one original and/or candidate process module to reach a state that meets at least one predetermined criterion.

5. The method of claim 1 , wherein the pool of available process modules comprises, for each available process module, a mapping between services provided by each available process module and process functions from a predetermined list.

6. The method of claim 5 , wherein the pool of available process modules further comprises, for each available process module, a mapping between service parameters and limits of these service parameters, and function parameters of the process functions and limits of these function parameters.

7. The method of claim 1 , wherein the services comprise one or more of:
heating or cooling a substance, and/or keeping the temperature of the substance at a desired value;
stirring a substance;
filling at least one vessel with a desired amount of a substance;
discharging a desired amount of a substance from at least one vessel;
dosing a desired amount of a second substance into a first substance;
intermixing a mixture of two or more substances by mechanical interaction with this mixture;
distilling at least one substance from a mixture of two or more substances;
transitioning at least one substance; and
inertizing at least one substance.

8. The method of claim 1 , wherein the resource and/or capability comprises a quantity of at least one educt processed per unit time, and/or a quantity of at least one product produced per unit time.

9. The method of claim 1 , wherein the resource and/or capability comprises a measurement range, and/or a dynamic range of at least one measurement instrument of the original process module or of the candidate process module, respectively.

10. The method of claim 1 , wherein determining whether a candidate process module from the pool of available modules fits into the given topology comprises:
for each input port of the original process module that is utilized according to the given topology, determining whether the candidate process module has a corresponding input port;
for each output port of the original process module that is utilized according to the given topology, determining whether the candidate process module has a corresponding output port; and
when it is determined that the candidate process module has a corresponding port for each utilized input port and output port of the original process module, determining that the candidate process module fits into the given topology.

11. The method of claim 10 , wherein a corresponding input port of the candidate process module is an input port that serves the same process function as the input port of the original process module, and a corresponding output port of the candidate process module is an output port that serves the same process function as the output port of the original process module.

12. The method of claim 11 , wherein determining whether a candidate process module from the pool of available modules fits into the given topology further comprises:
determining whether, in a state where all connections to input and output ports of the candidate process module have been made according to the given topology, all input and output ports of the candidate process module that are required for running the utilized services of the candidate process module are connected; and
in response to determining that a utilized service of the candidate process module cannot run because a connection to an input or output port is missing, determining that the candidate process module does not fit into the given topology.

13. The method of claim 1 , further comprising:
in response to determining that two or more candidate process modules have a same theoretical utilization that is the same or higher than the theoretical utilization of the original process module, choosing the candidate process module with a lowest total number of input and output ports as the candidate process module to replace the original process module.

14. The method of claim 1 , further comprising:
for two or more candidate process modules having theoretical utilizations that are at least as high as the theoretical utilization of the original process module, evaluating a value of at least one predetermined key performance indicator that will ensue when the original process module is replaced by the candidate process module, and choosing the candidate process module with a best resulting value of the key performance indicator as the candidate process module to replace the original process module.

15. The method of claim 14 , wherein the key performance indicator specifically comprises one or more of: a cost of executing the industrial process; a tota

Assignees

• Abb Schweiz Ag

Inventors

• Hoernicke Mario
• Stark Katharina
• Schulz Dirk

Classifications

• G06Q50/04

  Manufacturing · CPC title

• G06Q10/06 Primary

  Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling · CPC title

• G05B2219/31054

  Planning, layout of assembly system · CPC title

• Y02P90/30

  Computing systems specially adapted for manufacturing · CPC title

• G05B19/41865 Primary

  characterised by job scheduling, process planning, material flow · CPC title