Automated Reconfiguration of a Control Loop

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This patent proposes a method and device for the automated reconfiguration of control loops in technical processes, such as in industrial automation systems. If a component failure (e.g., sensor or actuator fault) is detected, a 'virtual controller' is automatically inserted between the main controller and the process, modifying the signals exchanged to maintain system operation despite the fault. The approach uses mathematical models created during a design phase to automatically adjust the control logic during operation, without needing to physically replace or modify the main controller.

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

• Industrial automation systems where reliability is critical, such as manufacturing lines.
• Safety-critical systems like nuclear plants or aerospace applications that require fault tolerance.
• Process control in the chemical, pharmaceutical, or food industry where downtime is costly.
• Automation environments utilizing programmable logic controllers (PLCs) that need minimal engineering changes in the event of component failures.
• Systems integrating redundant components (both physical and analytical redundancies) that need seamless failover during operations.

BenefitsContent extracted from patent full text and abstract with AI.

• Minimizes downtime and production losses caused by controller or component failures.
• Reduces the need for costly physical hardware redundancy and associated installation costs.
• Automatic and seamless system recovery with minimal manual intervention required.
• No need to redesign or replace the existing controller logic, allowing for easy integration into existing systems.
• Improves operational safety and reliability by ensuring systems continue functioning even during faults.
• Applicable to a wide range of discrete event-driven processes and automation environments.
• Offers a cost-effective and versatile solution for achieving real fault tolerance in industrial control systems.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method and an apparatus for automated reconfiguration of a control loop (1) for controlling a technical process. This firstly involves the creation in a design phase, of a mathematical model of the nominal control section of the control loop (1) and of nominal dynamics for the process. Next, in a runtime phase, a fault ascertained by means of the fault diagnosis unit (6) prompts automatic reconfiguration of the control loop (1) on the basis of the created mathematical model by virtue of a virtual controller (R) introduced between the controller (5) and the control section obtaining fault coverage by translating the communication.