Procedure for operating a system with a digital twin
Patent Information
- Application Number
- BR112025021359
- Authority / Receiving Office
- BR · BR
- Patent Type
- Applications
- Publication Date
- 2026-09-01
Smart Images

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Description
1 / 16 “PROCESS FOR OPERATING A SYSTEM WITH A DIGITAL TWIN”
[001] The present invention relates to a process for operating a system, especially an electro-hydrostatic actuator, a calculation unit and a computer program for its implementation, as well as such system. Background of the invention
[002] In many fields, systems such as electro-hydrostatic actuators are used. One application case is, for example, the use of an electro-hydrostatic actuator underwater, for example, to actuate valves in oil pipelines or similar. In this application, but also in others, the highest possible system availability is desirable. Description of the invention
[003] According to the invention, a process for operating a system, a calculation unit and a computer program for its implementation are proposed, as well as such a system with the characteristics of the independent claims. Advantageous configurations are the subject of the dependent claims as well as the following description.
[004] The invention relates to systems in which operational quantities or their values are detected, for example, by means of sensors, in order to then, based on this, determine control quantities or values by means of which the system is controlled. This can occur, for example, within the scope of a control or regulation. In this sense, the detected values of the operational quantities can be real values, the values of the control quantities, then theoretical values of theoretical quantities. In a preferred embodiment, a system is configured that has an electrohydrostatic actuator or such. But similarly, considerations are taken into account. Petition 870250090093, dated 03 / 10 / 2025, page 9 / 37 2 / 16 tion also other control systems, for example, electric actuators or generally electro-hydraulic actuators; by control system is meant a system or device by means of which certain functions can be controlled, for example valves can be opened and closed. In the case of an electrohydrostatic actuator, for example, the actuator can actuate the valve. Instead of a valve, other devices can also be actuated by means of the system.
[005] The aforementioned electro-hydrostatic actuator may comprise, for example, a calculation unit for control or regulation (control or regulation unit), an electric drive unit (e.g., electric motor), a hydraulic circuit with adjustment valves, the actuator itself, and possibly safety springs or similar. The actuator may then be coupled to the valve to be actuated, for example, through an appropriate interface. In addition, several sensors are typically present to measure various operational quantities, i.e., to detect values of operational quantities. Such operational quantities include, for example, the position of the actuator as well as one or more pressures in the system; i.e., a position sensor (or angle sensor, depending on the type of actuator) as well as pressure sensors may be provided.
[006] Based on the values of the operational quantities, the values for the control quantities can then be determined. Control quantities may include the speed of the electric drive unit, as well as the position of one or more control valves (or adjustment valves). In this sense, it may be a matter of usual actuator control or regulation.
[007] Especially complex and compact systems or siste Petition 870250090093, dated 03 / 10 / 2025, page 10 / 37 3 / 16 but control systems often require a high degree of integration, reliability, and safety. This is especially true when they are used in remote and difficult-to-access locations, such as at sea or generally underwater. To achieve all these factors, it may be necessary to implement redundancy in the system's controls, sensor systems, and actuators.
[008] Physical redundancy leads to higher system complexity, greater space requirements, and higher costs, especially when expensive materials such as refined steel are needed to protect sensitive hardware from environmental effects. In the underwater processing and underwater production industry, for example, it is common to redundantly manufacture control units or control circuit boards, sensors, and drive units to ensure reliable operation for a planned lifespan of, for example, at least 25 years in extremely deep waters.
[009] The restriction of magnitudes often required, however, restricts, in such complex systems, the possibilities of components and, therefore, requires alternative strategies to increase system reliability, when this is necessary.
[0010] Against this backdrop, the use of a so-called digital twin is proposed for redundancy purposes. In the case of this digital twin, it is a model faithful to reality or a simulation model, which is specifically designed in such a way that it runs on the calculation unit or control or regulation unit (also known as the drive unit control), that is, it is integrated and implemented there. It is also possible that the model is integrated or provided in another calculation unit, that is, different from the control or regulation unit, but this other calculation unit is provided locally in the control unit or Petition 870250090093, dated 03 / 10 / 2025, page 11 / 37 4 / 16 adjustment, i.e., for example, in a common or similar housing. This can be convenient when the computing capacity of a common control or adjustment unit is insufficient.
[0011] A corresponding process for operating a system, such as, for example, the electro-hydrostatic actuator explained above, can therefore be carried out, especially in a calculation unit or control or regulation unit or in a calculation unit different from the control or regulation unit, and comprises the following steps:
[0012] Values of one or more operational quantities of the system are provided or obtained by the system, especially by one or more system sensors, for example, in the unit of calculation to be performed. In the case of these values, they may be measurement values from the sensors. Within the scope of a control or regulation, values of one or more control quantities for the system are determined based on the values of said one or more operational quantities, which are also provided. The values of said one or more control quantities may be output to the system, especially a drive unit of the system. In this case, it may be a typical control or regulation.
[0013] Furthermore, based on the values of said one or more operational quantities, and on the values of one or at least one of the various control quantities, by means of a system model (i.e., for example, the so-called digital twin), values of one or more system monitoring quantities are determined and specifically evaluated. Said one or more system monitoring quantities then correspond to one or more of the various operational quantities of the system. In other words, by means of the system model, comparative values can be determined digitally in relation to the measured values. Petition 870250090093, dated 03 / 10 / 2025, page 12 / 37 5 / 16 sensor action.
[0014] If necessary, the values of said monitoring quantity, or at least one of several monitoring quantities, may be used during control or regulation, instead of the values of the respective operating unit. Possible and preferred criteria regarding whether and when the values of the monitoring quantities are used instead of the values of the operating quantities are explained in detail below. A simple example would be a detected sensor defect.
[0015] In this way, not only can the system be monitored, but digital redundancy is also created for, for example, the sensors already in the system, so that at least one of the several sensors can be replaced, if necessary, by the model or by values determined digitally by means of the model. Thus, the reliability or availability of the system can be increased without adding new components.
[0016] At this point it should be mentioned that the steps explained describe the general operation of the system, that is, these steps are repeated and performed over a longer period of time. It is understood that, for example, initially the values of the monitoring quantities are not used during control or regulation, but are continuously determined based on obtained control quantities or their values. Subsequently, values, or possibly several, monitoring quantities may be used instead of corresponding operational quantities during control or regulation. The quantities then substituted may, but do not need to, be considered when subsequently determining the monitoring quantities. If, for example, a sensor defect is detected, it can be foreseen that the values of the operational quantity in question will not be used, and instead, the values of the monitoring quantity will be used. Petition 870250090093, dated 03 / 10 / 2025, page 13 / 37 6 / 16 For example, the values of the monitoring quantities in question, along with the values of other operational quantities, are used to determine, through the model, the values of all monitoring quantities. In this sense, the values of monitoring quantities are not only used in control or regulation, but also when determining the values of the monitoring quantities, instead of the values of the respective corresponding operational quantity.
[0017] The system model or simulation model can be shaped or implemented in different ways. For example, one can use a purely physically motivated model, in which the system's relationships are illustrated, for example, through differential equations. This is also referred to as a "First Principles Model". Similarly, the system can be illustrated via a purely data-driven model or one operated with data. Here, for example, artificial intelligence, such as a neural network, which mimics the system's function, can be considered. Such a data-driven model can usually be trained beforehand, i.e., for example, with the aid of known values of operational and control quantities (called training data). This model can also be designated as a machine learning model. However, a combination of two types of models can also be used, that is, physically motivated and data-driven models.Thus, for example, some aspects are illustrated via differential equations, additional aspects which, for example, can hardly be illustrated via equations, but in compensation via data-based model proportion. Here, for example, frictional or similar forces are taken into consideration.
[0018] In one embodiment, based on the values of said one or at least one of several operational quantities and / or. Petition 870250090093, dated 03 / 10 / 2025, page 14 / 37 7 / 16 Based on the values of said one or at least one of several control quantities, the model is updated. In this case, one can also speak of a learning or adaptation of the model. For this, for example, state quantities (or state parameters) of the system, such as system efficiency, as well as one or more system friction factors, can always be repeated (or determined), so that, if necessary, the system model can be updated. Thus, for example, a value of a control quantity that becomes increasingly larger over time, with a constant value of the operational quantity, may indicate that friction has increased. This, in itself, does not represent any faulty functioning of the system, but only aging. The latter, however, must also be illustrated later in the model, to obtain values as accurate as possible of the monitoring quantities throughout the entire period of use.However, various indicators of wear or aging processes, or other information, are also taken into consideration. In this case, the state quantities do not necessarily need to describe the system itself, but may, for example, also describe the device to be actuated by the system, i.e., the valve mentioned. Changes to the device to be actuated by the system also have an effect on the system itself.
[0019] In one embodiment, information relating to such quantities of the device to be activated by the system can also be determined and issued. Thus, for example, the device to be activated can be developed and maintained.
[0020] In one embodiment it is further determined whether a faulty function of the system exists or can be expected, and this based on the values of, for example, at least one of the following quantities: said one or said at least one of several quantities of Petition 870250090093, dated 03 / 10 / 2025, page 15 / 37 8 / 16 monitoring, said one or at least one of several operational quantities, and said one or at least one of several control quantities. Thus, for example, a comparison can be made between the values of the operational quantity and the corresponding monitoring quantity. When a deviation between these values is greater than a predetermined or expected limit value, a malfunction can be assumed. A defective sensor would, for example, permanently deliver a value of zero, which will lead to a deviation. But even a permanent deviation could indicate a malfunction. If a sensor fails suddenly, the malfunction is detected directly; on the other hand, when a deviation increases over time, one can assume, for example, that a sensor failure should be expected.
[0021] When a system malfunction exists or can be expected, it can be determined that the values of said one or at least one of the various monitoring quantities can be used in the control or regulation, and then, especially, also used, i.e., instead of the values of the operational quantity itself. This is especially the case when the malfunction exists in a sensor. Alternatively, it can also be provided that, when a system malfunction exists or can be expected, it is verified whether the values of said one or at least one of the various monitoring quantities can be delivered according to a verification criterion to the control or regulation module or to the control or regulation.When the verification criterion is met, it is determined that the values of said one or at least one of the monitoring quantities can be used in control or regulation, and then also used to maintain the system's service provision until repairs can be made through planned maintenance. Petition 870250090093, dated 03 / 10 / 2025, page 16 / 37 9 / 16
[0022] With the verification criterion, it is possible to verify or decide, for example, whether the malfunction is in a sensor or, possibly, in an actuator or in another part of the system.
[0023] The use of an extremely reliable digital twin (or model) of a system therefore allows a combination of all available sensors to generate virtual redundancy, which does not require any additional building space or physical complexity for the system. The digital twin can be designed in such a way that it can automatically learn the behavior of the system during use. It can monitor the behavior of components when a component malfunction occurs. Thus, systems that are both reasonably priced, i.e., economical, and reliable can be provided at the same time.
[0024] In the field of renewable energies and CO2 storage in the underwater industry, for example, economical systems or components are required which offer a high degree of reliability and controllability, since they are installed up to several kilometers below sea level and hundreds of kilometers from the coast. Due to these extreme demands, a system used there must be able to perform tasks for several weeks or years, even after a system malfunction, before maintenance can be performed.
[0025] Physical redundancy can be avoided and replaced through virtual redundancy via a digital twin, which, for example, can be activated when a relevant event occurs during the replacement, and the accumulated knowledge about the system before the failure can enable a user to continue operating the system even after a component fails. This leads to an optimization of operational costs, since the system can automatically react to malfunctions and, for example, can provide tam Petition 870250090093, dated 03 / 10 / 2025, page 17 / 37 10 / 16 also information about the urgency of maintenance and repair.
[0026] A calculation unit according to the invention, for example, a control or regulation unit for an electrohydrostatic actuator, or also a separate calculation unit, which is intended for local use with such a control or regulation unit, is designed, especially from the point of view of program technique, to perform a process according to the invention.
[0027] The invention also relates to a system with one or more sensors for detecting values of one or more operational quantities of the system, with a drive unit, and with a calculation unit according to the invention. In particular, the system may comprise an electro-hydrostatic actuator or be configured as such.
[0028] It is also advantageous to implement a process according to the invention in the form of a computer program or a computer program product with program code for carrying out all the procedural steps, since this results in particularly low costs, especially when a control device is already in use for other tasks and is therefore already present. Suitable data storage media for providing the computer program are especially magnetic, optical and electrical memories, such as hard disks, Flash memories, EEPROMs, DVDs, SD cards, among others. It is also possible to download a program over computer networks (Internet, Intranet, etc.).
[0029] Other advantages and configurations of the invention result from the description and the accompanying drawing.
[0030] It is understood that the characteristics mentioned above and those clarified below can be used not only in the respective combination indicated, but also in others with Petition 870250090093, dated 03 / 10 / 2025, page 18 / 37 11 / 16 combinations or individually, without departing from the scope of the present invention.
[0031] The invention is represented schematically in the drawing with the aid of an embodiment and is described in detail below with reference to the drawing. Description of figures:
[0032] Figure 1 schematically shows a system according to the invention in a preferred embodiment;
[0033] Figure 2 schematically shows a flowchart to illustrate a process according to the invention in a preferred embodiment. Detailed description of the drawing.
[0034] Figure 1 shows a system 100 according to the invention in a preferred embodiment. For example, in the case of system 100, it is an electro-hydrostatic actuator, which is shown schematically with some components. For example, the electro-hydrostatic actuator has a calculation unit 110 configured as a control or regulation unit, an electrical drive unit 120, a hydraulic circuit 122 comprising adjustment or control valves (for example, electromagnetically controllable valves), safety springs 14, optionally including a control for this purpose, the actuator 126 itself as well as a mechanical interface 128.
[0035] In addition, the electro-hydrostatic actuator 100 has sensors 130, by means of which, for example, a position of the actuator 126, as well as one or more pressures in the hydraulic circuit 122 can be detected or measured. The measurement values can be transmitted to the calculation unit.
[0036] In addition, a valve 140 is shown schematically, which must be actuated by means of the electro-actuator. Petition 870250090093, dated 03 / 10 / 2025, page 19 / 37 12 / 16 hydrostatic 100. For this purpose, the electro-hydrostatic actuator 100 can be coupled to the valve 140 via the mechanical interface 128. In the case of valve 140, for example, it is a valve in an oil pipeline, pipe or similar, which, for example, is located underwater and, if necessary, must be able to be activated. For example, in the case of valve 140, it is a rotary valve; correspondingly, the actuator 126 can also be configured as a rotary actuator, or also as a linear actuator. It should be mentioned that the valve 140 to be controlled can be distinguished from any adjustment or control valves integrated into the system 100 as part of the hydraulic system. Instead of valve 140, other parts or components can also be controlled or actuated in another way by means of the system 100.In addition, other communication or data lines may eventually be provided to send adjustment commands from outside to the electro-hydrostatic actuator.
[0037] Figure 2 schematically represents a flowchart illustrating a process according to the invention, in a preferred embodiment. For this purpose, the calculating unit 110 as well as the system 100 of Figure 1 are shown schematically, wherein the system 100 may then have, for example, the components shown in the figure with the exception of the calculating unit 110.
[0038] In calculation unit 110, a control and regulation module 200 and a redundancy module 240 are shown as examples. These two modules perform different tasks, and the representation given here is only as separate modules, although it could be different; certain tasks can be performed, for example, by calculation unit 110, independently of the concrete implementation. In general, however, one can speak of an “Embedded Controller Application Software”. As Petition 870250090093, dated 03 / 10 / 2025, page 20 / 37 13 / 16 As already mentioned, the 240 redundancy module could also be implemented in another computing unit or a separate computing unit, in which case appropriate data communication would be provided.
[0039] When operating system 100, values (measurement values) of, for example, various operational quantities 220 of system 100, here the electrohydrostatic actuator, can be continuously detected; for this purpose, the sensors shown in figure 1 are used. The values of the operational quantities 220 are obtained in the calculation unit 110; it may also be foreseen that the calculation unit controls the sensors for the detection of the values in an appropriate manner.
[0040] The detected values of the operational quantities 220 can be delivered to the control or regulation model 200 possibly after processing and / or integration in a transmission module 210. There, within the scope of a control or regulation, based on the values of the quantities 220, values of, for example, various control quantities 230 are determined for the system 100. These values are output to the system 100 possibly after processing and / or integration in the transmission module 210, that is, the system 100 is controlled in a manner corresponding to the values of the control quantities 230. In this case, one can also speak of control signals that are output to the system 100. Especially in this case, for example, the electric drive unit shown in Figure 1 as well as the adjustment valves can be controlled appropriately.
[0041] This evolution of a control or regulation of system 100 may correspond to a usual control or regulation, in which, for example, the valve 140 shown in figure 1 is opened or closed as needed, for which the actuator 126 has Petition 870250090093, dated 03 / 10 / 2025, page 21 / 37 14 / 16 that must be moved appropriately.
[0042] In addition, the aforementioned redundancy module 240 is provided, which detects or represents a digital twin. The redundancy module 240 comprises, for example, the model 242 of system 100, an evaluation module 244 (to update parameters or state quantities from model 242, for example, friction, efficiency, resistances), a fault module 246, as well as a decision module 248. It is also worth noting that these different modules do not necessarily need to be implemented separately in the software; instead, what matters are their tasks or functions.
[0043] In the case of model 242, it may be, for example, a physically motivated model, a data-based model, or a combination of both, as previously explained. With model 242, system 100, here the electro-hydrostatic actuator, is illustrated or represented. The model then obtains, in particular, the operational quantities 220 and the control quantities 230 or their (actual) values as input values. Based on this, the values of monitoring quantities 250 can then be determined using the model. The monitoring quantities 250, corresponding especially to the operational quantities 220, are not measured, however, by means of sensors, but rather digitally by means of the model. Thus, as the actual operational quantities 220 adjust or result from the establishment of values of the control quantities 230, the monitoring quantities 250 or their values can be determined based on the values of the control quantities 230.At this point, the values of quantities 220 are not necessary for determining the values of the monitoring quantities, but they can be used to obtain more accurate values.
[0044] In model 242, as mentioned, the system is illustrated. Petition 870250090093, dated 03 / 10 / 2025, page 22 / 37 15 / 16 100. This also especially includes the fact that, in this case, state quantities (or state parameters) such as efficiency or friction factors in the system are illustrated. In the case of such state quantities, these are especially quantities that can change over time, for example, with the aging of the system. Thus, for example, efficiency may decrease over time or friction may increase, for example, due to wear.
[0045] The evaluation module 244 can receive, as input values, the operational quantities 220 and the control quantities 230 or their (current) values. In addition, the state quantities 250 or their current values can be known. Based on the operational quantities 220 and the control quantities 230 or their values, the state quantities 252 can be continuously redetermined or re-evaluated; if necessary, that is, when the state quantities 2522 have changed, for example, by a certain value, the model 242 can be updated accordingly. Thus, the model 242 always illustrates, as accurately as possible, the current state of the system, especially including any aging of the system. Thus, for example, a value of a control quantity that increases over time, with the value of the operational quantity remaining constant, may indicate that friction has increased.
[0046] The fault module 246 receives as input values, for example, the values of the updated model variables or state quantities and / or the operational quantities 220 and / or the control quantities 230, as well as, for example, the state quantities 252. Based on this, it is then possible to determine whether fault operation exists or at least can be expected, that is, for example, within a certain time in the future. This is the case, for example, when a monitoring quantity determines Petition 870250090093, dated 03 / 10 / 2025, page 23 / 37 16 / 16 nothing through the model deviates clearly from the corresponding operational values or such deviation increases over time. When this is the case, it is determined that faulty operation is present or can be expected.
[0047] Decision module 248 receives, as input, the finding of whether a malfunction is present or expected. Based on this information, it can then be determined whether the values of the operational quantities continue to be used in the control or regulation module 200 or whether, eventually, in the case of an operational quantity, the values to be used should be replaced by the values of the corresponding monitoring quantities – which are determined digitally by means of model 242. If a replacement must occur, the values of the monitoring quantity in question can then be passed from the redundancy module 240 to the control or regulation module 200, and the control or regulation module 200 can be instructed to immediately use the values of the monitoring quantity instead of the operational quantity. In this way, the operation of system 100 remains possible with acceptable accuracy, at least for a certain time.The objective, then, is primarily to continue providing the system's main service with a minimally acceptable quality until maintenance is possible, or until the end of the system's lifespan, for example, when that decision is made. This information can be communicated, for example, via a communication interface (e.g., CAN or Ethernet), and then a decision can be made as to whether operation should continue or whether a replacement of the equipment should be made. That is, at least errors are detected or anticipated (as in "condition monitoring"), but, in addition, system operation can be continued, possibly with restricted functionalities. Petition 870250090093, dated 03 / 10 / 2025, p. 24 / 37
Claims
1 / 4 CLAIMS 1. Process for operating a system (100), characterized in that it comprises: - providing values of one or more operational quantities (220) of the system by the system, especially by one or more sensors (130) of the system, - providing values of one or more control quantities (230) for the system, which were determined within the scope of a control or regulation, based on the values of one or at least one or more quantities (220), - determining, based on the values of said one or at least one of the operational quantities (220), and the values of said one or at least one of the control quantities (230), by means of a model (242) of the system, especially an integrated model, values of one or more monitoring quantities (250) of the system, wherein said one or more monitoring quantities (250) of the system corresponds (m) to said one or at least one of the various operational quantities (220) of the system, - provide,in case of need, values of said one or at least one of several monitoring quantities (250), for use in control or regulation, instead of the values of the respective corresponding operational quantity (220), to transmit the values of said one or several control quantities (230) to the system (100), especially a drive unit of the system.
2. Process according to claim 1, characterized in that, based on the values of said one or at least one of said several operational quantities (220) and / or based on the values of said one or at least one of said several control quantities (230), the model (242) is updated.
3. Process according to claim 2, characterized Petition 870250090093, of 03 / 10 / 2025, page 25 / 37 2 / 4 by the fact that the model (242) is updated by updating one or more state quantities (252), said one or more state quantities especially comprising at least one of the following quantities: an efficiency of the system and / or a device to be actuated by means of the system, one or more friction factors of the system and / or the device to be actuated by means of the system, one or more indicators of wear or aging process.
4. A process according to any of the preceding claims, characterized in that information about one or more of the quantities of a device to be actuated by means of the system is determined and transmitted, especially one of the following quantities: an efficiency of the device to be actuated by the system, one or more friction factors of the device to be actuated by means of the system, one or more indicators of wear or aging process of the device to be actuated by means of the system.
5. A process according to any of the preceding claims, characterized in that it further comprises: • determining whether a system malfunction exists or can be expected, based on the values of at least one quantity, preferably at least one of the following quantities: - said one or at least one of several monitoring quantities (250), - one or several state quantities, - said one or at least one of several operational quantities (220), - said one or at least one of several control quantities (230), and • determining when a system malfunction Petition 870250090093, dated 03 / 10 / 2025, p.26 / 37 3 / 4 exists, or when it is expected that the values of said one or at least one of said several monitoring quantities can be used in control or regulation, or • verify when a faulty system operation exists or can be expected, if the values of said one or at least one of said several monitoring quantities can be used in control or regulation according to a verification criterion, and • determine that the values of said one or at least one of said several monitoring quantities can be used in control or regulation, when the verification criterion is met.
6. Process according to claim 4, characterized in that a faulty operation is determined to exist or be expected when a deviation between the values of said one or one of several monitoring quantities (250) and the corresponding operational quantity (220) is greater than a predetermined limit value or can be expected.
7. Process according to any of the preceding claims, characterized in that the system (100) has an electro-hydrostatic actuator or is configured as such, wherein the electro-hydrostatic actuator has an electric drive unit (120), one or more control valves and an actuator (126), and / or wherein the system is an underwater system.
8. Process according to any of the preceding claims, characterized in that said one or more operating quantities (220) of the system comprise one or more of the following operating quantities: an actuator position, one or more pressures in the system.
9. Process in accordance with any of the preceding claims Petition 870250090093, of 03 / 10 / 2025, page 27 / 37 4 / 4, characterized in that said one or more control quantities (230) for the system comprises one or more of the following control quantities: a speed of the electric drive unit, and a position of one or more control valves.
10. Computing unit (110) characterized in that it comprises a processor, which is configured so that it performs the process as defined in any of the preceding claims.
11. System (100), especially a submarine system, characterized in that it has one or more sensors (130) for detecting values of one or more operational quantities (220) of the system, with a drive unit (120), and with a calculation unit (110) as defined in claim 10.
12. Computer program characterized in that it comprises commands which, when executed by a computer, cause the computer to perform the process as defined in any one of claims 1 to 9.
13. Computer-readable data storage, characterized in that the computer program as defined in claim 12 is stored on it. Petition 870250090093, dated 03 / 10 / 2025, pp. 28 / 37