Automated Reconfiguration of a Control Loop

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This patent describes a method and device for automatically reconfiguring control loops in technical or industrial processes—particularly when components like sensors or actuators fail or experience faults. The system relies on a mathematical model of the process, built during a design phase. If an error is detected during operation, a reconfiguration component intercepts and modifies the control signals and sensor data exchanged between the controller and the process, maintaining process requirements without the need for manual intervention or hardware replacement.

Use CasesContent extracted from patent full text and abstract with AI.

• Industrial automation systems that need to remain operational despite sensor or actuator failures.
• Manufacturing lines where downtime due to hardware faults can be costly.
• Safety-critical facilities (e.g., chemical plants, nuclear power, aviation systems) where continuous control is essential.
• Automated logistics systems (like conveyor networks) requiring self-healing in case of blockages or component malfunctions.
• Process control in smart factories utilizing Industry 4.0 concepts.

BenefitsContent extracted from patent full text and abstract with AI.

• Reduces downtime and maintenance costs by automatically compensating for hardware faults without manual repairs.
• Enhances system fault-tolerance and reliability, ensuring continuous operation even in case of component failures.
• Minimizes costs compared to traditional hardware redundancy, since no duplicate equipment is necessary.
• Improves safety by maintaining control of critical processes despite faults.
• Eases integration into existing systems because the original controller logic does not need to be altered; adaptation happens as an intermediate layer.
• Allows for flexible, versatile deployment across different types of control loops and automation equipment.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method and to a device for the automated reconfiguration of a control loop (1) for controlling a technical process. First, in a design phase, a mathematical model of the nominal controlled system (4) of the control loop (1) and of nominal dynamics of the process is created. Thereafter, in a runtime phase, if there is an error determined by means of the error diagnostic unit (6), the control loop (1) is automatically reconfigured on the basis of the created mathematical model, in that event strings (SEN, AKT) exchanged between the controller (5) and the controlled system (4) are automatically changed in dependence on the error by intervention (SEN', AKT') in order to effect a fulfillment of the defined requirements (S).