Method for calibrating physical unit and system for calibrating and adjusting physical unit

Abstract

The invention relates to a method for calibrating a physical unit (12) and a system (10) for calibrating and adjusting a physical unit. The physical unit is arranged in the real process environment (14). A virtual component (26) disposed in a virtual process environment (24) is provided. The virtual process environment is formed to correspond to the real process environment such that the physical units arranged in the real process environment are represented in a manner corresponding to the virtual components (26) in the virtual process environment. Measurements are performed with a physical unit to obtain true measurements. The measurement is simulated with a virtual component to obtain a virtual measurement value. The offset is determined by a verification unit (30) based on a comparison of the real measurement and the virtual measurement. The real measurement value corresponds to the virtual measurement value. The physical unit is calibrated by the verification unit using at least the offset such that the compensation data based on the offset takes into account future measurements for the physical unit.

Description

Technical Field

[0001] The present invention relates to a method for calibrating a physical unit and a system for calibrating and adjusting a physical unit. Background Technology

[0002] To obtain accurate and reliable measurements, physical units, such as measuring cells, must be calibrated or adjusted in a time-based or event-based manner. Time-based calibration can be performed at discrete points in time or at regular intervals. On the other hand, event-based calibration may rely on detected differences between the actual values ​​of the physical unit and their associated setpoints. If this difference becomes too large, calibration may be triggered. Event-based calibration can also be triggered by external events (such as ambient temperature, pressure ratio) or by manual operation.

[0003] In this context, calibration refers to the comparison and / or alignment with a physical reference of a physical unit that has specified set values. The degree of difference between the measurements recorded using the physical unit and the measurements obtained using the physical reference is then determined.

[0004] Adjustment refers to intervention in the device to improve measurement accuracy. This can be done through maintenance work and / or by inputting updated operating parameters that directly affect how measurements are recorded, thereby improving accuracy. For example, adjustment is necessary due to the aging process of physical units or significant changes in external environmental conditions.

[0005] According to previous methods, physical units need to be removed from the main plant (which is, for example, part of the process environment) so that the physical units can be compared with a physical reference at the same location under the same conditions. This often results in plant shutdown or at least limited plant operability, thus reducing plant efficiency. Summary of the Invention

[0006] The purpose of this invention is to improve factory efficiency.

[0007] According to the present invention, the objective is achieved by calibrating a physical unit. This physical unit is arranged in a real process environment, such as in a plant, like a process plant. The method includes at least the following steps.

[0008] Virtual components are provided within a virtual process environment. Therefore, these virtual components are provided in digital form, which is why they can also be called digital components. The virtual process environment is configured to correspond to the real process environment, such that physical units arranged in the real process environment are represented in a manner corresponding to the virtual components in the virtual process environment. In this respect, the real process environment is virtualized and modeled to obtain the virtual process environment. In other words, the virtual process environment is equivalent to a virtual copy of the real process environment.

[0009] Perform real measurements using physical units in a real process environment to obtain real measurement values.

[0010] Virtual measurements are obtained by simulating measurements using virtual components within a virtual process environment. Therefore, virtual measurements are simulated measurements of virtual components within the virtual process environment.

[0011] The verification unit determines the offset based on a comparison of the actual measurement value and the virtual measurement value. The actual measurement value corresponds to the true value of the physical unit, while the virtual measurement value is the setpoint used for the physical unit. The verification unit performs this comparison between the true value and the setpoint to determine the deviation, i.e., the offset. The offset is then used to determine compensation data, which specifies how to interpret the relationship between the actual measurement value and the setpoint. The actual measurement value and the virtual measurement value correspond to each other. In other words, the actual measurement value (true value) is compared with the specified virtual measurement value (setpoint).

[0012] The verification unit calibrates the physical unit using at least an offset, such that compensation data based on that offset takes into account future measurements applied to the physical unit. Compensation data is determined based on a defined deviation, i.e., the offset, and takes into account at least future measurements applied to the physical unit. Furthermore, the compensation data can be used to subsequently correct measurements already obtained from the physical unit. In any case, correction allows for more accurate measurements of the physical unit to be obtained.

[0013] This method is based on the finding that a virtual process environment can be designed that corresponds to, or is a replica of, the real process environment. Virtual components corresponding to physical units exhibit time characteristics that correspond to the time characteristics of the physical units.

[0014] Even though virtual components in a virtual process environment typically represent physical units in a manner corresponding to those in a real process environment, unknown influencing factors may arise that affect the physical units. These factors, such as unpredictable changes in environmental conditions, can cause discrepancies between the temporal behavior of the physical units and the virtual components. The lack of consideration for the effects of aging or wear of the physical units in the virtual components can also lead to these discrepancies. Consequently, real-world measurements obtained using the physical units often do not match the virtual measurements simulated using the virtual components, resulting in further discrepancies.

[0015] Compensation data does not need to be written to the physical unit, but it can be taken into account through a device connected to the physical unit (e.g., an evaluation device). In particular, this can avoid adjusting the physical unit, i.e., installing updated operating parameters or performing maintenance work on the physical unit, at least for a period of time, thereby improving the efficiency of the physical unit and, consequently, the efficiency of the plant using the physical unit.

[0016] The fundamental advantage of this method is that the physical unit or the factory that provides the physical unit can continue to operate without restriction, that is, without interruption.

[0017] The physical unit can have a measurement unit, particularly a sensor or sensor-actuator system, such as a mass flow controller. The physical unit can also be a field device that includes a corresponding measurement unit.

[0018] In (process engineering) plants, a large number of such physical units are typically implemented, so this method can significantly improve efficiency because it is applicable to all physical units. In this respect, the plant does not need to be shut down at least partially for the calibration of physical units.

[0019] A real process environment refers to the actual environment in which physical units are deployed, i.e., in a factory, such as a manufacturing plant. A real process environment possesses environmental characteristics that are prevalent around the physical units and influence their operating modes, such as temperature, pressure, lighting conditions, material composition, electromagnetic interference fields, and other environmental parameters. These influencing factors affect the operating modes of the physical units over time. In particular, due to these environmental characteristics, the physical units may exhibit behavior that changes over time.

[0020] A virtual process environment reproduces a real process environment in order to simulate environmental characteristics that are prevalent in the real process environment for virtual components. This causes the virtual components to exhibit behaviors that reproduce the environmental characteristics of the real process environment. In other words, a virtual process environment can be considered a simulation of the real process environment.

[0021] Typically, physical references are assigned to physical cells. These physical references are deployed in a real laboratory environment, which is why they are also called real references. Unlike in a real process environment, defined and consistent environmental conditions exist universally in a real laboratory environment. This means that a real process environment differs from a real laboratory environment. The physical reference always emits the correct values.

[0022] The main difference between a physical reference and a physical cell lies in their measurement accuracy. A physical reference typically has a measurement accuracy at least ten times higher than that of a physical cell.

[0023] The virtual component can be compared, indirectly or directly, with a physical reference used for the physical cell, thereby leveraging the high accuracy of the physical reference used for the virtual component, and subsequently using that high accuracy to calibrate the physical cell. Since the virtual component is used for calibration, it is not necessary to remove the physical cell and / or physical reference from their respective environments.

[0024] On the one hand, it is stipulated that virtual components are virtual references modeled based on physical references assigned to physical units. These physical references are arranged in a real laboratory environment. In contrast, virtual references are arranged in a virtual process environment. As explained above, the real process environment differs from the real laboratory environment.

[0025] In this configuration of the method, the virtual reference possesses the characteristics of a physical reference for the physical unit, namely, particularly, higher measurement accuracy compared to the physical unit. The physical unit is then calibrated directly based on the virtual reference. In this respect, the virtual and physical references differ only in their respective environments, as the virtual reference is provided in a virtual process environment (i.e., an environment corresponding to the real process environment providing the physical unit). In contrast, the physical reference is provided in a real laboratory environment, which differs from the real process environment.

[0026] Therefore, the behavior of physical references in a real process environment is simulated using virtual references within a virtual process environment. Since the environmental conditions in a real process environment differ from those in a real laboratory environment, the behavior of physical references in a real process environment differs from that in a real laboratory environment. Therefore, the behavior of physical references within the environment in which the physical unit resides is simulated.

[0027] The behavior of a physical reference in a real process environment is modeled. In the simulation, an environmental offset can be considered, reflecting the environmental changes between the real laboratory environment and the real process environment.

[0028] Therefore, virtual references in a virtual laboratory environment modeled on a real laboratory environment will be represented in a manner corresponding to physical references in the real laboratory environment.

[0029] Taking into account the additional environmental offset between the virtual laboratory environment and the virtual process environment, the behavior of the virtual reference in the virtual process environment can be determined. In this respect, the behavior of the virtual reference in the virtual process environment corresponds to the behavior of the physical reference in the real process environment, which is why physical units can be calibrated.

[0030] Environmental offset can be determined based on environmental conditions between the real process environment and the real laboratory environment, for example, by a validation unit. Alternatively, environmental offset can, of course, be determined by another device and then transmitted to the validation unit.

[0031] In another embodiment of the method, the virtual component is a virtual unit modeled based on the physical unit. Therefore, the virtual component is a digital twin of the physical unit. This virtual unit is formed in a virtual process environment such that the virtual unit formed in the virtual process environment is represented in a manner corresponding to the physical unit arranged in the real process environment. Ultimately, the virtual component in this embodiment of the method is a simulation of the physical unit. Because the virtual process environment is modeled based on the real process environment, the virtual unit is represented in a manner corresponding to the physical unit. Due to the corresponding behavior of the virtual unit to the physical unit, in this case, the virtual unit can be easily used to calibrate the physical unit.

[0032] For example, in this configuration of the method, a virtual reference is additionally provided based on the physical reference modeled to the physical unit. As explained above, the physical reference is arranged in a real laboratory environment, while in this case, the virtual reference is arranged in a virtual laboratory environment, which is configured to correspond to the real laboratory environment. The real process environment is different from the real laboratory environment. This simulates two virtual components: a virtual unit and a virtual reference. The respective environment of each virtual component represents a copy of the real environment of the associated physical component. The virtual unit is arranged in a virtual process environment, which is a copy of the real process environment providing the physical unit, while the virtual reference is arranged in a virtual laboratory environment, which is a copy of the real laboratory environment providing the physical reference. In other words, corresponding digital twins are generated for the two physical components, and these digital twins are provided in simulated copies of the environments of the physical components.

[0033] Specifically, virtual references in a virtual laboratory environment are represented in a manner corresponding to physical references in a real laboratory environment. This reduces the simulation workload of virtual references compared to implementations that place virtual references within a virtual process environment.

[0034] Optionally, before calibrating the physical cells using the virtual cells, the verification unit compares the virtual cells with a virtual reference. Specifically, the verification unit verifies whether the virtual cells match the virtual reference. If not, calibration is performed to first calibrate the virtual cells using a virtual reference arranged in a virtual laboratory environment. The virtual cells calibrated in this way can then be used to calibrate the physical cells arranged in the real process environment.

[0035] In other words, virtual calibration can be achieved by determining compensation data for the virtual cell based on a virtual reference. As explained above, the compensation data can be calculated. Then, whenever a deviation between the physical and virtual cells is detected, the physical cell can be calibrated in a simple way by simply applying or setting the previously determined compensation data. In other words, synchronization only occurs between the physical and virtual cells because the virtual cell has already been calibrated using the virtual reference, and therefore the virtual cell is in a calibrated state.

[0036] Furthermore, the verification unit can specifically compare the virtual reference with the physical reference before calibrating the physical unit using the virtual unit. In this way, the verification unit checks the reference setpoint specified by the physical reference against the actual virtual reference value of the virtual reference. If the verification unit detects a reference offset between the physical reference value (i.e., the reference setpoint) and the virtual reference value (i.e., the actual reference value), the verification unit determines reference compensation data based on this offset and considers this compensation data when interpreting the virtual reference value. As explained above, if the virtual reference is arranged in a virtual process environment rather than a virtual laboratory environment, environmental offset can also be considered here.

[0037] The verification unit can compare the virtual reference with the physical reference at regular time intervals. The appropriate time interval can be determined by user input.

[0038] According to one aspect, the verification unit takes into account the environmental offset of the virtual laboratory environment, which depends on the virtual reference. This environmental offset allows for the selective simulation of the behavior of the virtual reference in either the virtual process environment or the virtual laboratory environment. In particular, the environmental offset enables the use of virtual components as virtual references in the virtual process environment, thus eliminating the need for simulation of the virtual unit itself.

[0039] In some implementations, the verification unit calibrates the physical unit using virtual components when event-based and / or time-based triggering conditions are met.

[0040] Event-based triggering conditions specifically involve the offset between the actual measurement and the corresponding virtual measurement. In this case, the verification unit compares the offset between the actual and virtual measurements with a difference threshold. If the offset is greater than the difference threshold, the process is triggered. Offset verification can be performed by the verification unit at discrete time points or at regular time intervals.

[0041] Optionally, the difference threshold can be deterministic, and in particular adjustable. For example, the difference threshold can be set by maintenance personnel as needed. Event-based triggering conditions ensure a reduction in calibration workload, as calibration is only performed when necessary.

[0042] Alternatively, event-based triggering conditions can also include user input, i.e., manual triggering.

[0043] Furthermore, event-based triggering conditions can be based on external events, such as ambient temperature and / or pressure ratio.

[0044] Time-based triggering conditions involve calibrating physical units at predetermined time intervals. Maintenance personnel can adjust and set these intervals. This means that calibration is performed independently of the aforementioned offset. Time-based triggering conditions ensure continuous calibration of the physical units.

[0045] This means that the verification unit triggers the calibration of the physical unit using virtual components under the following conditions:

[0046] - At regular, pre-defined time intervals, and / or

[0047] - When the verification unit determines that the offset is greater than or less than a predetermined threshold (depending on the sign), and / or

[0048] - Responds to user input.

[0049] Specifically, the calibration must be performed at regular, pre-defined time intervals, but it must also be performed when a corresponding event occurs, i.e., when there is user input or the offset exceeds a threshold.

[0050] In some implementations, data from the physical unit is provided to the virtual component to obtain virtual measurements. This data can be input data from the physical unit. This means that the input data used to obtain the real measurements is also used to obtain the virtual component. This ensures that the same data basis is used for the physical unit and the virtual component, and that, generally, the real measurements should correspond to the simulated virtual measurements without deviating from the process conditions.

[0051] If the calibration of the physical unit still results in an offset, adjustments to the physical unit can be performed. The verification unit can detect whether the calibration of the physical unit still results in an offset by determining a new (updated) offset, specifically greater than a predetermined difference threshold, within a predetermined time interval after the compensation data has been determined and applied. In other words, after the calibration of the physical unit, at least within a determined time interval, it is assumed that the determined offset does not exceed or fall below the predetermined difference threshold (depending on the sign). If this condition is not met, the physical unit must be adjusted. In this case, the verification unit can issue an appropriate notification to the user, informing them that the adjustment of the physical unit is necessary.

[0052] Specifically, the adjustment includes setting at least one new parameter in a real process environment and / or manually adjusting the physical unit. Manual adjustment of the physical unit may include maintenance measures. Setting at least one new parameter may be performed as part of a firmware update.

[0053] In one implementation of this method, if the calibration of the physical unit using the virtual component fails, the verification unit issues a notification or message. The fact that the virtual component calibration failed can have several causes, in particular:

[0054] - The verification unit determines that, after determining appropriate compensation data, a non-negligible offset (greater than / less than a specified difference threshold) is detected again within a specified time interval, and / or

[0055] - The virtual reference assigned to the physical unit is inaccessible, and / or

[0056] - The virtual reference assigned to the virtual cell issues an error message, and / or

[0057] - The virtual unit does not exist or is inaccessible, and / or

[0058] - The virtual unit is issuing an error message.

[0059] This allows for various configurations to be considered to prevent the use of virtual components to calibrate physical units.

[0060] For example, in the event that calibration of a physical unit using virtual components fails, the verification unit issues a notification or message stating that the physical unit must be calibrated using a physical reference deployed in a real laboratory environment. Therefore, it can also indicate what steps need to be taken to perform the calibration of the physical unit.

[0061] Optionally, the verification unit issues a notification or message after the physical unit has been successfully calibrated. Information regarding the calibration can then be further processed, specifically by the verification unit. The time interval for time-based calibration can be restarted.

[0062] In principle, a notification can be sent to a user who must then be at least partially active, and the message is intended for automating the processing of information about the calibration that has been performed. For example, in automated processing, subsequent procedures can be initiated automatically.

[0063] According to one approach, a verification unit is coupled to a data memory, where determined compensation data from the verification unit is stored. Then, during operation, a component receiving the actual measurement values ​​from the physical unit can read the compensation data from the data memory and use this data to interpret the actual measurement values, thereby calibrating the actual measurement values ​​based on the previously determined compensation data. This achieves adjustable and reliable measurements without the intervention of the physical unit.

[0064] According to another aspect, the present invention also relates to a computer program product comprising instructions that, when executed by a processor, cause the processor to perform at least a portion of the methods described above, particularly the measurement, simulation, and calculation steps. The advantages achieved by the methods described herein are also correspondingly achieved by the computer program product.

[0065] According to an additional aspect, the present invention also relates to a computer-readable storage medium comprising instructions that, when a processor executes a computer program product, cause the processor to perform at least a portion of the methods described above, particularly the measurement, simulation, and calculation steps. The advantages achieved by the methods described herein are also correspondingly achieved through the computer-readable storage medium.

[0066] According to another aspect, the above-mentioned objective is achieved by a system for calibrating and adjusting physical units according to the present invention. The system has a real process environment in which physical units are arranged. The system has at least one processor configured to simulate a virtual process environment, which is configured to correspond to the real process environment, and virtual components are arranged within the virtual process environment. The system is configured to perform the above-described method.

[0067] The advantages achieved through this method are also realized through this system. In particular, the efficiency of the physical unit may be improved compared to previous methods because the physical unit is calibrated based on virtual components, thus eliminating the need to remove the physical unit from the factory for calibration.

[0068] Specifically, the processor is configured to simulate virtual components in a cloud environment. This enables distributed access to the virtual components, allowing the simulated topology to be used for calibration of different physical units.

[0069] The verification unit can coordinate the calibration and / or adjustment of the physical unit.

[0070] For this purpose, the verification unit can be designed to simulate an independent service in the topology, such as in the cloud, on a server, or on an edge device.

[0071] Alternatively, the verification unit can also be designed as a software and / or hardware module located within a control center coupled to the physical unit or the factory that provides the physical unit.

[0072] In principle, virtual components and virtual environments, i.e., virtual process environments and / or virtual laboratory environments, can be simulations. This means that virtual measurements corresponding to setpoints used for physical units can be simulated for the past, present, and / or future.

[0073] Artificial intelligence can be used to determine compensation data and / or reference compensation data. Attached Figure Description

[0074] The invention, along with other advantageous embodiments and developments thereof, will now be described and illustrated in more detail with reference to the examples shown in the accompanying drawings, in which:

[0075] - Figure 1 A system for calibrating and adjusting physical units according to the present invention is shown.

[0076] - Figure 2 Another system for calibrating and adjusting physical units according to the present invention is shown, and

[0077] - Figure 3 An overview of a method for calibrating physical units according to the present invention is shown. Detailed Implementation

[0078] All features mentioned below regarding the exemplary embodiments and / or drawings may be combined individually or in any sub-combination of the features of the invention (including features of the preferred embodiments).

[0079] Figure 1 A system 10 for calibrating and adjusting physical unit 12 according to an embodiment is shown.

[0080] System 10 includes a physical unit 12, which may include a measurement unit, such as a sensor or a sensor-actuator system.

[0081] The physical unit 12 is arranged in a real process environment 14, i.e., implemented in a factory such as a process plant.

[0082] Physical reference 16 is assigned to physical cell 12. Physical reference 16 is placed in a real laboratory environment 18. In this respect, it is ensured that physical reference 16 always provides the correct value to physical cell 12. In other words, physical reference 16 represents the primary reference.

[0083] While the physical reference 16 is generally under defined and constant environmental conditions in the real laboratory environment 18, the real process environment 14 has different and particularly variable environmental conditions that affect the operating principle of the physical unit 12. Although the physical unit 12 generally has an operating principle that matches that of the physical reference 16, the deviations and variations in environmental conditions still cause the measurements of the physical unit 12 to deviate from the reference values ​​of the physical reference 16.

[0084] Furthermore, the physical reference 16 differs from the physical unit 12 in that the measurement accuracy of the physical reference 16 is at least 10 times higher than that of the physical unit 12. Therefore, the physical reference 16 can be used as a calibration device.

[0085] According to this embodiment, system 10 includes processor 20 for simulating virtual environment 22.

[0086] exist Figure 1 In the example shown, virtual environment 22 corresponds to virtual process environment 24, through which the real process environment 14, in which physical units 12 are arranged, is modeled. In particular, the potentially variable environmental conditions that are common in the real process environment 14 are modeled in virtual process environment 24.

[0087] Furthermore, the processor 20 simulates at least one virtual component 26 arranged in the virtual process environment 24. This means that the virtual component 26 is exposed to varying environmental conditions modeled in the virtual process environment 24. Therefore, the virtual component 26 is exposed to the same environmental conditions as the physical unit 12, since the virtual process environment 24 is a replica of the real process environment 14.

[0088] according to Figure 1 In the example implementation, virtual component 26 is a virtual reference 28 modeled based on real reference 16, but arranged in a replica of the real process environment 14, i.e., arranged in virtual process environment 24. Therefore, virtual reference 28 is not arranged in the virtual laboratory environment, thus exposing virtual reference 28 to conditions other than those of real reference 16.

[0089] Conversely, if the physical reference 16 is arranged in the real process environment 14, the virtual reference 28 exhibits behavior corresponding to the physical reference 16 in the virtual process environment 24. In other words, the behavior of the physical reference 16 in different environments (i.e., the real process environment 14) is simulated.

[0090] Since the real process environment 14 differs from the real laboratory environment 18, for example in terms of environmental conditions, an environmental offset occurs. Taking the environmental offset into account, the virtual reference 28 in the virtual process environment 24 behaves in a manner similar to that of the physical reference 16 in the real process environment 14.

[0091] Of course, a virtual reference 28 is formed so that the virtual reference 28 also has a high accuracy corresponding to the accuracy of the physical reference 16.

[0092] Additionally, a verification unit 30 is provided, for example, provided by the processor 20, i.e., as a software-based module, indicated in this case by a dashed arrow. For example, the verification unit 30 is a service executed on the processor 20. Alternatively, the verification unit 30 may be a hardware module located in a specific location, particularly as part of the factory implementing the physical unit 12, or located in a control center.

[0093] Since the virtual component 26, i.e. the virtual reference 28, behaves in the virtual process environment 24 in the same way as the physical reference 16 in the real process environment 14, the virtual component 26 can be used by the verification unit 30 to calibrate the physical unit 12 in the real process environment 14.

[0094] Verification unit 30 may optionally first compare virtual reference 28 with physical reference 16 to ensure that virtual reference 28 provides the same value as physical reference 16 in the same environment, such as in a laboratory environment.

[0095] In this regard, the verification unit 30 can access the physical unit 12, the physical reference 16, and the virtual component 26, in particular their respective measured values ​​or reference values.

[0096] Verification unit 30 can obtain virtual measurement values ​​from virtual components 26. To this end, verification unit 30 provides each virtual component 26 with data from physical unit 12, or more precisely, with input data from physical unit 12, i.e., the data on which physical unit 12 issues the actual measurement values. Since the virtual process environment 24 is typically configured to correspond to the real process environment 14, the virtual measurement values ​​of the virtual components 26 should ultimately, ideally, correspond to the actual measurement values ​​of physical unit 12 under the calibration state of physical unit 12.

[0097] The offset between the actual measurement value (true value) recorded by the physical unit 12 and the virtual measurement value (set value) provided by the virtual component 26 is equivalent to a change in the state of the physical unit 12, resulting in the physical unit 12 no longer being considered calibrated.

[0098] This offset can then be used by the verification unit 30 to determine compensation data to be considered when recording future real measurements via the physical unit 12, so that the behavior of the physical unit 12 is adapted to the behavior of the virtual component 26. This makes it possible to calibrate the physical unit 12 without deactivating and / or removing it from the real process environment 14. Therefore, an instantaneous comparison of the physical unit 12 with a physical reference 16 in the real laboratory environment 18 is not necessary.

[0099] This can minimize or even completely avoid downtime of physical unit 12 and the factory where physical unit 12 is located, thereby improving operational efficiency.

[0100] System 10 also has at least one user interface 36, which is coupled at least to processor 20, since verification unit 30 is implemented in software. If verification unit 30 is at least partially implemented in hardware, then user interface 36 may also be provided on verification unit 30 as an alternative or in addition to processor 20.

[0101] User interface 36 enables verification unit 30 to send notifications to users of system 10 or receive user input, such as specifying parameters.

[0102] Additionally, system 10 includes at least one data memory 38, which is at least indirectly coupled to verification unit 30. Compensation data determined by verification unit 30 can be stored in data memory 38, allowing it to be used by a user or downstream component, such as an evaluation device, to interpret the actual measurements recorded using physical unit 12. This prevents the intrinsic parameters of physical unit 12 from having to be changed. Instead, compensation data that enables the determined offset to be compensated can be read from data memory 38 and taken into account when interpreting the actual measurements of physical unit 12.

[0103] also, Figure 1 The simulation of a virtual environment 22 and a verification unit 30 within a cloud environment 40 is shown. In this respect, the processor 20 may be part of a server.

[0104] Alternatively, processor 20 can be located in an edge device.

[0105] Figure 2 An example implementation of system 10 is shown, wherein the virtual environment 22 and Figure 1 The difference in the virtual environment 22 is that the virtual component 26 is now a virtual unit 32, which is configured to correspond to the physical unit 12. The virtual unit 32 is arranged in the virtual process environment 24.

[0106] in addition, Figure 2 Virtual environment 22 and Figure 1 The difference in the virtual environment 22 is that an additional virtual laboratory environment 34 is simulated within the virtual environment 22 by the processor 20. The virtual laboratory environment 34 is configured to correspond to the real laboratory environment 18.

[0107] In this configuration, the processor 20 can simulate additional virtual components 26 in the form of a virtual reference 28, in addition to the virtual unit 32. The virtual reference 28 is assigned to the virtual unit 32 and positioned within the virtual laboratory environment 34. The virtual reference 28 is configured to correspond to the physical reference 16.

[0108] according to Figure 2 The specific design of the virtual environment 22 is such that each physical component, namely physical unit 12 and physical reference 16, has a digital twin assigned to it, namely virtual unit 32 and virtual reference 28.

[0109] from Figure 3 The differences between the two systems (10) are clearly visible. Figure 3 An overview of the method for calibrating physical unit 12 is shown, with optional steps indicated by dashed lines.

[0110] In the first step S1, the verification unit 30 uses the virtual component 26 to check whether the triggering condition of the method is met, that is, whether the calibration of the physical unit 12 is to be triggered.

[0111] The triggering condition can be based on the fact that a predetermined time interval has been established; that is, the triggering condition can be time-based. The predetermined time interval can be specified by the user of system 10, for example, using user interface 36.

[0112] Alternatively, a difference threshold can be used to determine the triggering condition in an event-based manner. In this case, verification unit 30 repeatedly determines the offset between the real measurement value recorded using physical unit 12 and the virtual measurement value simulated using virtual component 26, and compares this offset with the difference threshold. If the offset determined in this way is greater than / less than (depending on the sign) the difference threshold, the triggering condition may be met. Of course, the difference threshold can be specified by the user of system 10, for example, using user interface 36.

[0113] In another alternative, the trigger condition can also be triggered immediately in an event-based manner as a result of user input via user interface 36. The trigger condition can also be satisfied in an event-based manner via a trigger signal from another component (e.g., a higher-level control device).

[0114] In the next step S2 of the method, a virtual component 26 formed in the virtual process environment 24 is provided.

[0115] Virtual component 26 can be implemented in two different ways.

[0116] According to step S3, the virtual component 26 is formed in such a way as Figure 1 The virtual reference 28 is shown in the virtual process environment 24. The virtual reference 28 is formed in the virtual process environment 24 to model the physical reference 16 assigned to the physical unit 12. Thus, in this case, the physical reference 16 is arranged in the real laboratory environment 18, while the virtual reference 28 is arranged in the virtual process environment 24.

[0117] Therefore, step S3 can be further developed by step S4, in which the behavior of the physical reference 16 in the real process environment 14 is simulated by the virtual reference 28 in the virtual process environment 24. To achieve this, an environmental offset reflecting the difference between the real process environment 14 and the real laboratory environment 18 can be specifically taken into account by the verification unit 30 as part of step S4.

[0118] As an alternative to steps S3 and S4, the virtual component 26 can also be formed as a virtual unit 32 in step S5 after step S2. This virtual unit 32 is arranged in the virtual process environment 24, such as... Figure 2 As shown.

[0119] Virtual unit 32 is simulated by processor 20, making it the same type as physical unit 12. Since the virtual process environment 24 is modeled based on the real process environment 14, the behavior of virtual unit 32 in virtual process environment 24 corresponds to the behavior of physical unit 12 in real process environment 14. This virtual unit 32 is also referred to as a digital twin of physical unit 12.

[0120] According to the configuration of the virtual environment 22, the processor 20 is able to simulate the virtual reference 28 in step S6. The virtual reference 28 is arranged in the virtual laboratory environment 34. The virtual laboratory environment 34 is modeled based on the real laboratory environment 18. The virtual reference 28 is formed to correspond to the physical reference 16, therefore, the virtual reference 28 in the virtual laboratory environment 34 behaves in the same way as the physical reference 16 in the real laboratory environment 18. The virtual reference 28 is also referred to as a digital twin of the physical reference 16.

[0121] Based on the different configurations of the virtual environment 22 according to step S4 or step S6, the method then includes the following step S7.

[0122] In step S7, the verification unit 30 compares the virtual reference 28 with the physical reference 16. The environment of the virtual reference 28 must be considered here. The physical reference 16 is always arranged in a real laboratory environment 18. However, the virtual reference 28 can be arranged in a virtual process environment 24 (according to...). Figure 1 Steps S3 and S4), or in the virtual laboratory environment 34 (according to Figure 2 (Steps S5 and S6). Therefore, depending on the configuration, environmental offset must be considered when comparing virtual reference 28 with physical reference 16.

[0123] In the configuration of virtual environment 22, no virtual reference 28 is provided; instead, only virtual units 32 arranged in virtual process environment 24 are provided. Virtual components 26 are formed by virtual units 32 (i.e., step S6 is omitted). Verification unit 30 compares each virtual unit 32 with physical reference 16. Since the virtual units 32 are arranged in virtual process environment 24, environmental offset must also be considered, reflecting the difference between the real process environment 14 and the real laboratory environment 18.

[0124] If the virtual environment 22 has both virtual unit 32 and virtual reference 28, the method may include subsequent steps S7 and S8, wherein the verification unit 30 compares the virtual unit 32 with the virtual reference 28. The verification unit 30 then takes into account that the virtual unit 32 is arranged in the virtual process environment 24, while the virtual reference 28 is arranged in the virtual laboratory environment 34. In this respect, environmental offset may also be considered here.

[0125] Depending on the configuration of the virtual environment 22, step S9 follows either step S7 or step S8. In step S9, a measurement is performed using physical unit 12 to obtain the actual measurement value. This measurement can be performed or at least triggered by verification unit 30.

[0126] In step S10, the verification unit 30 then simulates the measurement using the virtual component 26 in the virtual process environment 24 to obtain a virtual measurement value. Naturally, the virtual measurement value obtained from the verification unit 30 corresponds to the actual measurement value recorded in the previous step S9.

[0127] Step S10 can be further developed through step S11, in which the verification unit 30 provides data from the physical unit 12 to the virtual component 26 to obtain a virtual measurement value. This means that the verification unit 30 uses the input data or input signal of the physical unit 12 to provide the same data to the virtual component 26 and obtains a virtual measurement value based on that data.

[0128] After step S10, the method includes step S12, in which the verification unit 30 determines the offset based on a comparison of the real measurement value obtained in step S9 and the virtual measurement value obtained in step S10.

[0129] In the subsequent step S13, the verification unit 30 determines any compensation data for future measurements of the physical unit 12 based on the determined offset. The determined compensation data is then used by the verification unit 30 to compensate the physical unit 12. The compensation data can also be used for past measurements of the physical unit 12, i.e., retrospectively.

[0130] This means that compensated data is used to calibrate future real measurements and / or already obtained measurements (retrospectively) recorded using physical unit 12. This ensures the reliability of the recorded real measurements. In particular, this makes it possible to calibrate physical unit 12 without removing it from the real process environment 14 and without comparing it to physical reference 16.

[0131] Preferably, the verification unit 30 can output the determined compensation data to the user or store the determined compensation data in other components, such as in the data memory 38.

[0132] The method can also be further developed by an optional step S14, in which the verification unit 30 issues a notification or message when an incorrect calibration occurs.

[0133] This notification can be output to the user by the verification unit 30 using the user interface 36. Alternatively, a communication interface can be used to provide the message in signal form to other components for (partially) automated further processing. This information can also be output by the verification unit 30 to external components, such as the factory's control center, to which physical unit 12 is part.

[0134] Specifically, the calibration is incorrect if the following conditions occur:

[0135] - After determining the corresponding compensation data, the verification unit 30 determines that, within a specified time interval, a non-negligible offset between the newly recorded real measurement value and its corresponding virtual measurement value is detected again, and / or

[0136] - Virtual reference 28 assigned to physical unit 12 is inaccessible, and / or

[0137] - The virtual reference 28 assigned to virtual unit 32 sends an error message, and / or

[0138] - Virtual unit 32 is inaccessible or does not exist, and / or

[0139] - Virtual unit 32 sent an error message.

[0140] All these events make it impossible to perform a reliable calibration on physical unit 12 that is effective at least for a certain period of time. Therefore, it must be assumed that the calibration is incorrect.

[0141] Optionally, in step S14, the verification unit 30 may provide a description in the issued notification or message that the physical unit 12 will be calibrated using the physical reference 16 and / or the physical unit 12 will be adjusted.

[0142] However, the method also includes step S15, in which the verification unit 30 issues a notification or message if the calibration of the physical unit 12 is successful. The assumption that the calibration has been successfully completed can be based on the verification unit 30 determining, after the calibration has been completed, that there is no deviation or only an allowable deviation.

[0143] Specifically, based on the messages from steps S14 and S15, process automation regarding physical unit 12, including the calibration of physical unit 12, is achieved. In the context of process automation, one of the triggering conditions outlined in step S1 can be considered.

[0144] Figure 1 The system 10 shown is with Figure 2 The difference between the systems 10 shown is reflected in the method in which the virtual unit 32 is always calibrated using the virtual reference 28, so that the virtual unit 32 is always in a calibrated state.

[0145] If step S12 determines that there is an offset between virtual unit 32 and physical unit 12, then virtual unit 32 and physical unit 12 can be synchronized. This results in calibration because virtual unit 32 has already been calibrated using virtual reference 28.

[0146] Typically, the virtual reference 28 is continuously compared with the physical reference 16 to ensure that the correct value is always available in the virtual environment 22. This method allows the physical unit 12 to be calibrated. This enables the physical unit 12 to be calibrated without removing it from the factory, thereby improving efficiency.

Claims

1. A method for calibrating physical units (12) arranged in a real process environment (14), wherein, The method includes at least the following steps: - Provide virtual components (26) formed in a virtual process environment (24), wherein the virtual process environment (24) is configured to correspond to the real process environment (14), such that the physical units (12) arranged in the real process environment (14) are represented in a manner corresponding to the virtual components (26) in the virtual process environment (24). - The physical unit (12) is used to perform the measurement to obtain the actual measurement value. - The virtual component (26) is used to simulate measurements to obtain virtual measurement values. - The offset is determined by means of a verification unit (30) based on a comparison of the real measurement value and the virtual measurement value, wherein the real measurement value and the virtual measurement value are corresponding, and - The physical unit (12) is calibrated using at least the offset by means of the verification unit (30), such that future measurements of the physical unit (12) take into account the compensation data based on the offset.

2. The method according to claim 1, characterized in that, The virtual component (26) is a virtual reference (28) modeled based on a physical reference (16) assigned to the physical unit (12), wherein the physical reference (16) is arranged in a real laboratory environment (18), and the virtual reference (28) is arranged in the virtual process environment (24), wherein the real process environment (14) is different from the real laboratory environment (18).

3. The method according to claim 2, characterized in that, The behavior of the physical reference (16) in the real process environment (14) is simulated by the virtual reference (28) in the virtual process environment (24).

4. The method according to claim 1, characterized in that, The virtual component (26) is a virtual unit (32) modeled based on the physical unit (12), wherein the virtual unit (32) is formed in the virtual process environment (24) such that the virtual unit (32) formed in the virtual process environment (24) is represented in a manner corresponding to the physical unit (12) arranged in the real process environment (14).

5. The method according to claim 4, characterized in that, A virtual reference (28) is provided based on a physical reference (16) assigned to the physical unit (12), wherein the physical reference (16) is arranged in a real laboratory environment (18), and the virtual reference (28) is arranged in a virtual laboratory environment (34) which is configured to correspond to the real laboratory environment (18), and wherein the real process environment (14) is different from the real laboratory environment (18).

6. The method according to claim 5, characterized in that, The virtual reference (28) in the virtual laboratory environment (34) is represented in a manner corresponding to the physical reference (16) in the real laboratory environment (18).

7. The method according to claim 5 or 6, characterized in that, Before calibrating the physical unit (12) by means of the virtual unit (32), the verification unit (30) compares the virtual unit (32) with the virtual reference (28).

8. The method according to any one of claims 5 to 7, characterized in that, The verification unit (30) will take into account the environmental offset of the virtual laboratory environment (34) depending on the virtual reference (28).

9. The method according to any one of the preceding claims, characterized in that, When event-based and / or time-based triggering conditions are met, the verification unit (30) uses the virtual component (26) to calibrate the physical unit (12).

10. The method according to any one of the preceding claims, characterized in that, Data from the physical unit (12) is provided to the virtual component (26) to obtain virtual measurement values.

11. The method according to any one of the preceding claims, characterized in that, If the calibration of the physical unit (12) still results in an offset, an adjustment to the physical unit (12) is performed.

12. The method according to any one of the preceding claims, characterized in that, If the calibration of the physical unit (12) using the virtual component (26) fails, the verification unit (30) issues a notification or message.

13. The method according to any one of the preceding claims, characterized in that, The verification unit (30) issues a notification or message after the physical unit (12) has been successfully calibrated.

14. The method according to any one of the preceding claims, characterized in that, The verification unit (30) triggers the calibration of the physical unit (12) using the virtual component (26) under the following conditions: - At regular, pre-defined time intervals, and / or - When the verification unit (30) determines that the offset is greater than or less than a predetermined threshold, and / or - Responds to user input.

15. A system (10) for calibrating and adjusting a physical unit (12), wherein, The system (10) has a real process environment (14) in which the physical unit (12) is arranged, and wherein the system (10) has at least one processor (20) configured to simulate a virtual process environment (24) that is formed to correspond to the real process environment (14) and wherein virtual components (26) are provided in the virtual process environment (24), wherein the system (10) is configured to perform the method according to any one of the preceding claims.

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