System and method for reverse engineering a module for a modular industrial plant

A computer-implemented method for reverse engineering control logic of a module for a modular industrial plant, the method comprising:

• obtaining module-related data including runtime data relating to prior use of the module during a timeperiod, wherein during the timeperiod at least one piece of equipment of the module transitions from a first equipment state to a second equipment state, the runtime data including tags indicating the equipment state of the equipment at a plurality of timepoints during the timeperiod, wherein the equipment includes an actuator;
• inferring from the module-related data one or more actuator state transition conditions causing the actuator to transition from the first state to the second state, wherein causing the actuator to transition from the first state to the second state comprises:
• determining a default state for the actuator;
• evaluating a current service that includes the actuator, wherein evaluating the current service includes comparing the second state of the actuator in the current service with the first state in a previous service;
• and
• identifying process conditions leading to the transition of the actuator from the first state to the second state, wherein the process conditions are used to generate the reverse engineering control logic of actuator state changes within the current service based on the process conditions;
• creating a frame using an engineering tool for control software configured to implement the reverse engineering control logic based on the inferred module-related data, wherein further logic relating to transition states that are not reached in the runtime data is added to the reverse engineering control logic, wherein the frame is a machine-adaptable building block for manufacturing custom software, and wherein the reverse engineering control logic is added to the frame;
• utilizing the reverse engineering control logic in the engineering tool to reverse engineer actuator states based on the process conditions;
• and
• utilizing the frame created using the engineering tool to manufacture control software to replace a control system of the module, and executing the manufactured control software in the control system of the module to control and cause the actuator to transition between the first equipment state and the second equipment state under the identified process conditions.