Method for the automatic control of manufacturing processes

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Details

364140, 364147, 364192, G05B 1905

Patent

active

054503469

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

The invention relates to a method for the automatic control of batch processes by means of a process control in which automatic control programs access individual sequential controls.
Batch processes are processes in which the desired product is produced in a time-sequential succession of process-engineering subtasks according to a predetermined specification. The sequence of such processes can be controlled by means of an automatic process control. Such automatic process controls consist of two basic blocks, the hardware and the software.
The hardware components comprise one or more central processor units with internal or external storage units and input and output units, for example analog or binary input and output cards for communication with the systems to be controlled; keyboard, mouse or light pen for operating the process control and display screen or printer for observing the process control.
The software contains the formulation programs and/or general interlocking and/or sequence programs and the process-relevant software components. The formulation programs are the process specifications with the basic operations and their sequential organization for producing a product in the batch process to be controlled. Such formulation programs are usually structured into partial formulations which control the parallel or sequential execution of subtasks in different process units.
The elementary modules of the formulation programs or partial formulations are the phases. The phase programs are structured into the control part (sequential part), the parameter part and the communication part. The control part contains the program elements for the step sequence of the basic operations of the process with the particulars of the initial conditions, the process steps and their combination, the final conditions and the step sequence in the event of malfunctions. The parameter part for controlling a chemical process may comprise, for example, the feedstocks and their amount, the normal time for a process step, the process variables (setpoint values and limiting values for temperature, pressure etc.) and the permissible operating actions. The communication part contains the program components for the data exchange between the phases and the data exchange with the operator for signaling faults or the current state of the process. The communication part further contains the program elements for activating the process-relevant software of the individual control level, that is to say the individual control modules which effect, for example, the activation of the controllers, valves or motors of the process system.
The process-relevant software, that is to say the modules for individual activation, are programs which are activated by the sequence programs (formulation) and convert their commands for controlling one or more operands (actuators), for example controllers, valves, motors.
FIG. 1 shows the principle of the process control of a batch process corresponding to the prior art: The formulation program for controlling the entire process contains a plurality of partial formulations, called automatic control programs here. During the program execution, the automatic control programs directly access the hardware of the plant or activate one or more individual control modules for the activation or interlocking of controllers, valves or motors. In this process, the individual control modules activate, in each case, an actuator in the field. During the sequence of the process control, feedback on the state of the equipment in the field is given to the individual control level or to the automatic control programs and to the process operating/process monitoring system.
During the program execution, different automatic control programs in some circumstances simultaneously access one individual control module or one actuator in the field. The frequency of such simultaneous activations or the interlockings thereof increases drastically with increasing complexity of the software programs. If, in

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Siemens "CEMAT 16", 1974, Best.Nr. E 265, 2021, 1-10.

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