Complete equipment operation simulation system and complete equipment operation simulation method

Abstract

In a packaged plant operation simulation system, a control device gives a time stamp to a snapshot of an operation result of a control function of the control device at an arbitrary time, and transmits the snapshot to a simulator, and the simulator performs an accelerated operation using the operation result included in the snapshot transmitted from the control device and input data given a time stamp after the time indicated by the time stamp given to the snapshot, until the operation time of the current point of the control function of the control device is caught up, the accelerated operation performing an operation of a control model of the simulator at a faster cycle than the operation cycle of the control function of the control device.

Description

Technical Field

[0001] This invention relates to a complete set of equipment operation simulation system and a complete set of equipment operation simulation method.

[0002] This application claims priority based on Japanese Patent Application No. 2021-196649, filed with the Japan Patent Office on December 3, 2021, the contents of which are incorporated herein by reference. Background Technology

[0003] Patent document 1 describes an online simulation system consisting of a process control device and a simulator. The process control device controls the operating terminals such as valves or shock absorbers according to the state variables of the complete set of equipment, and the simulator is used for functional verification tests of the process control device.

[0004] In this system, the process control mode and simulation mode are switched online according to instructions from the user, and the input / output of the control device and the actual complete set of equipment is switched between the input / output of the control device and the complete set of equipment model in the simulator.

[0005] Previous technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 62-22101 Summary of the Invention

[0008] The technical problem to be solved by the invention

[0009] In the simulation system described in Patent Document 1, during the operation of the complete set of equipment by the control device in the normal control mode, it is impossible to confirm the action of the control function. Therefore, it is impossible to confirm in advance whether the output value from the control device to the complete set of equipment will change abruptly due to the change of the control logic of the control device (e.g., adjustment of control function parameters or circuit change).

[0010] In view of the above, at least one embodiment of the present invention aims to provide a complete set of equipment operation simulation system and a complete set of equipment operation simulation method that can confirm the impact of changes in the control logic of the control device controlling the complete set of equipment on the output value of the control device before changes are made during the operation of the complete set of equipment.

[0011] Methods for solving problems

[0012] To achieve the above objectives, at least one embodiment of the present invention includes a complete equipment operation simulation system comprising:

[0013] A control device having a control function, wherein the control function outputs output data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment; and

[0014] The simulator includes a control model that simulates the control functions of the control device and is time-synchronized with the control device.

[0015] The control device and the simulator receive the input data at the same period for both the control device and the simulator.

[0016] The simulator assigns a timestamp to the input data it receives and stores it in a storage device.

[0017] The control device assigns a timestamp to a snapshot of the calculation results of the control function at any given time, and transmits the snapshot to the simulator.

[0018] The simulator uses the calculation results contained in the snapshot transmitted from the control device and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, to perform accelerated calculations until it catches up with the current calculation time of the control function of the control device. The accelerated calculations perform the calculations of the simulator's control model at a cycle faster than the calculation cycle of the control function of the control device.

[0019] To achieve the above objectives, at least one embodiment of the present invention relates to a complete equipment operation simulation method that uses a control device and a simulator.

[0020] The control device has a control function, which outputs control data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment.

[0021] The simulator includes a control model that simulates the control functions of the control device and is time-synchronized with the control device.

[0022] The complete set of equipment operation simulation method includes the following steps:

[0023] The control device and the simulator receive the input data at the same period for both the control device and the simulator;

[0024] The input data received by the simulator is timestamped and saved.

[0025] A snapshot of the calculation results of the control function of the control device at any given time is timestamped, and the snapshot is transmitted to the simulator; and

[0026] The accelerated computation is performed using the computation results contained in the snapshot and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, until it catches up with the current computation time of the control function of the control device. The accelerated computation performs the computation of the simulator's control model at a cycle faster than the computation cycle of the control function of the control device.

[0027] Invention Effects

[0028] According to at least one embodiment of the present invention, a complete set of equipment operation simulation system and a complete set of equipment operation simulation method are provided, which can confirm the impact of changes in the control logic of the control device controlling the complete set of equipment on the output value of the control device before changes are made during the operation of the complete set of equipment. Attached Figure Description

[0029] Figure 1 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2A) involved in one implementation method.

[0030] Figure 2 This is a diagram illustrating an example of the hardware structure of the control device 4, the simulator 6, and the human-machine interface 8.

[0031] Figure 3 This is a timing diagram used to illustrate the method of reproducing the operating state of the complete set of equipment 100 using simulator 6.

[0032] Figure 4 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2B) according to another embodiment.

[0033] Figure 5 This is a timing diagram illustrating the method of reproducing the operating state of the complete set of equipment 100 using the simulator 6 for the complete set of equipment operation simulation system 2 (2B).

[0034] Figure 6 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2C) according to another embodiment.

[0035] Figure 7 This is a timing diagram illustrating another example of a method for reproducing the operating state of a complete set of equipment 100 using a simulator 6 for a complete set of equipment operation simulation system 2 (2A). Detailed Implementation

[0036] Hereinafter, some embodiments of the present invention will be described with reference to the accompanying drawings. The dimensions, materials, shapes, and relative arrangements of the constituent components described or illustrated as embodiments are not intended to limit the scope of the invention, but are merely illustrative examples.

[0037] For example, expressions such as "in a certain direction," "along a certain direction," "parallel," "orthogonal," "center," "concentric," or "coaxial" that indicate relative or absolute configuration not only indicate such configuration in a strict sense, but also indicate a state of relative displacement in a manner with tolerance or at an angle or distance that allows the same function to be obtained.

[0038] For example, expressions such as "same," "equal," and "homogeneous" that indicate that things are in the same state not only indicate the same state in a strict sense, but also indicate a state with a difference in tolerance or degree to which the same function can be obtained.

[0039] For example, the description of shape, such as quadrilateral or cylindrical shape, not only refers to the shape in the strict geometric sense, but also includes shapes with concave or convex parts or chamfers within the range where the same effect can be obtained.

[0040] On the other hand, the expression "possessing," "including," or "having" one constituent element is not an exclusive expression that excludes the existence of other constituent elements.

[0041] Figure 1 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2A) involved in one implementation method.

[0042] Figure 1 The complete equipment operation simulation system 2 shown includes a simulator 6 that functions as a control device 4 for controlling the complete equipment 100, a simulation control device 4, and a human-machine interface 8 for performing operations such as operating the complete equipment 100. The type of complete equipment 100 is not limited; for example, it can be a power plant or a chemical plant.

[0043] The control device 4, simulator 6, and human-machine interface 8 are interconnected via information communication network 10 and configured to communicate with each other. Furthermore, the control device 4 and simulator 6 are interconnected via a control communication network 12, which is different from the information communication network 10, and multiple input / output modules 14 are connected to the control communication network 12. Details of the functions of these structures will be described later.

[0044] Figure 2 This diagram illustrates an example of the hardware structure of the control device 4, the simulator 6, and the human-machine interface 8. Here, the same diagram will be used to briefly explain the hardware structure of each of the control device 4, the simulator 6, and the human-machine interface 8.

[0045] like Figure 2As shown, the control device 4, emulator 6, and human-machine device 8 are each configured using a computer that includes, for example, a processor 72, RAM (Random Access Memory) 74, ROM (Read Only Memory) 76, HDD (Hard Disk Drive) 78, input I / F 80, and output I / F 82, and they are interconnected via a bus 84. Furthermore, the hardware structure of each of the control device 4, emulator 6, and human-machine device 8 is not limited to the above, and can also be configured by a combination of control circuitry and storage devices. Moreover, the control device 4, emulator 6, and human-machine device 8 are each configured by executing programs that perform their respective functions using a computer. The functions of each of the control device 4, emulator 6, and human-machine device 8, as described below, are implemented for example as follows: loading the program stored in ROM 76 into RAM 74 for execution by the processor 72, and reading and writing data from RAM 74 and ROM 76. Alternatively, it can replace the HDD78 shown as an example of non-volatile memory, or use other non-volatile storage media such as SD / CF / SSD together with the HDD78. Furthermore, the program stored in ROM76 can also be stored in HDD78 or other non-volatile storage media and loaded into RAM74 for execution by processor 72.

[0046] like Figure 1 As shown, the control device 4 has a control function Mc for controlling the equipment 100, and uses the control function Mc to control the equipment 100. The control device 4 exchanges various data with the equipment 100 via at least one input / output module 14 (multiple input / output modules 14 in the illustrated example). The control function Mc of the control device 4 outputs output data for controlling the equipment 100 (e.g., control command values ​​for controlling the operating terminals of valves or shock absorbers included in the equipment 100) by receiving input data representing the state quantities of the equipment 100 from the equipment 100 via the input / output modules 14.

[0047] The simulator 6 has a control model Md that simulates the control function Mc of the control device 4, and the time of the control device 4 is synchronized with that of the simulator 6. Time synchronization between the control device 4 and the simulator 6 can be achieved, for example, by using a Precision Time Protocol (PTP). The control function Mc of the control device 4 and the control model Md of the simulator 6 can also be downloaded from the human-machine interface 8 and installed on the control device 4 and simulator 6 respectively.

[0048] The control device 4 and the simulator 6 receive each of all input data input from the equipment 100 via the input / output module 14 at the same period for both the control device 4 and the simulator 6. Furthermore, the simulator 6 assigns a timestamp to each of the input data received by the simulator 6 and stores it in the simulator 6's storage device (e.g., the simulator 6's HDD 78, etc.).

[0049] The human-machine interface 8 is a human-machine interface used by the operator to monitor and operate the complete set of equipment 100. The human-machine interface 8 includes a control logic modification unit 16 and an output data comparison unit 18.

[0050] Figure 3 This is a timing diagram used to illustrate the method of reproducing the operating state of the complete set of equipment 100 using simulator 6.

[0051] exist Figure 3 In the diagram, the horizontal axis ti (where i is an integer greater than or equal to 1) represents the respective computation time of the control device 4 and the simulator 6. For example... Figure 3 As shown, during the operation of the complete set of equipment 100, the simulator 6 is started, and the startup of the simulator 6 is completed at time t1 (step S11).

[0052] Next, the control device 4 assigns a timestamp to the snapshot Qn of the calculation result (intermediate value of the calculation of the control function Mc) of the control device 4 at any time tn after the simulator 6 starts, and stores it in the storage device of the control device 4 (e.g., RAM 74 of the control device 4). The snapshot Qn with the timestamp assigned to it at time tn is then transmitted to the simulator 6 (step S12). In the illustrated example, the control device 4 divides the snapshot Qn with the timestamp assigned to it at time tn into multiple data points and transmits these multiple data points to the simulator 6 over N calculation cycles. Here, N is a complex number, and the control device 4 transmits the snapshot Qn to the simulator 6 over N calculation cycles from time tn to time t(n+N). That is, the simulator 6 begins copying the calculation result of the control device 4 at time tn and completes the copying at time t(n+N).

[0053] Next, the simulator 6 uses the aforementioned calculation result (the calculation result of the control function Mc at time tn) contained in the snapshot Qn transmitted from the control device 4 and the aforementioned input data (the aforementioned input data stored in the simulator 6's storage device) with a timestamp after time tn (the time represented by the timestamp assigned to snapshot Qn) to perform accelerated calculation until it catches up with the current calculation time of the control function Mc of the control device 4 (step S13). The accelerated calculation performs the calculation of the simulator 6's control model Md at a cycle faster than the calculation cycle of the control function Mc of the control device 4. Hereinafter, "accelerated calculation" refers to the accelerated calculation of the simulator 6 in step S13 above. The simulator 6 uses the calculation result of the control function Mc at time tn contained in the snapshot Qn transmitted from the control device 4 as the initial value for the accelerated calculation. In the illustrated example, at time t(n+N), simulator 6 uses the calculation result of control function Mc at time tn (the intermediate value of control function Mc's calculation) and the aforementioned input data with a timestamp assigned after time tn (the aforementioned input data stored in the simulator 6's storage device) to begin accelerated calculation, and catches up with the calculation of control function Mc of control device 4 at time tm, thereby ending the accelerated calculation. Therefore, after time tm, the operating state of the complete equipment 100 can be reproduced using simulator 6.

[0054] Simulation of simulator 6 begins at time tm, and after time tm, the operation cycle of control function Mc of control device 4 becomes the same as the operation cycle of control model Md of simulator 6. Then, after time tm, i.e., after accelerated calculation, if operator operation control logic change unit 16 of equipment 100 changes the control logic of control model Md of simulator 6, output data comparison unit 18 compares the output data output from control model Md of simulator 6 with the output data output from control function Mc of control device 4. Output data comparison unit 18 may, for example, compare and display the output data of control device 4 and simulator 6 on a display device (not shown), or calculate the difference between the output value of control device 4 and the output value of simulator 6, and output an alarm sound and / or alarm display to notify of the risk of a sudden change in output value if the difference exceeds a threshold.

[0055] Here, we will explain the effects of the above-mentioned complete equipment operation simulation system 2.

[0056] In the aforementioned complete equipment operation simulation system 2, the simulator 6, which is time-synchronized with the control device 4 and has a control model Md with simulated control function Mc, uses the calculation result of time tn (an intermediate value of the calculation of control function Mc) contained in the snapshot Qn transmitted from the control device 4 and the input data (input data input from the complete equipment 100 to the simulator 6 via the input / output module 14 and stored in the simulator 6's storage device) after the time tn (the time represented by the timestamp assigned to the snapshot Qn) to perform accelerated calculations until it catches up with the current calculation time of the control function Mc of the control device 4. The accelerated calculations are performed on the control model Md of the simulator 6 at a cycle faster than the calculation cycle of the control function Mc of the control device 4. Therefore, the operating state of the complete equipment 100 at a certain point in time can be reproduced by the simulator 6, which is a device different from the control device 4. Therefore, when the control logic of the control device 4 is changed from this state, the simulator 6 can be used during the operation of the complete equipment 100 to confirm the impact of the change in control logic on the output value of the control device 4 (e.g., whether the output value of the control device 4 changes abruptly). This reduces the risk of the controlled object of the complete equipment 100 suddenly stopping or experiencing an unexpected accident.

[0057] Figure 4 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2B) according to another embodiment. Figure 5 This is a timing diagram illustrating the method of reproducing the operating state of the complete set of equipment 100 using the simulator 6 for the complete set of equipment operation simulation system 2 (2B).

[0058] Figure 4 The complete set of equipment operation simulation system 2 (2B) shown is Figure 1 The difference between the complete equipment operation simulation system 2 (2A) shown is that the simulator 6 has a complete equipment model Mp as a model of the simulated complete equipment 100, while the other basic structures are the same as those of the complete equipment operation simulation system 2 (2A). Figure 4 Unless otherwise specified, the complete equipment operation simulation system 2 (2B) involved in the illustrated embodiment is considered to be related to... Figure 1 The symbols used in the complete equipment operation simulation system 2 (2A) shown are identical to those used in other systems. Figure 1 The complete set of equipment operation simulation system 2 (2A) shown has the same structure for each component, and descriptions are omitted. Furthermore, in Figure 5 The timing diagram shows the operation and use of the control device 4 and the simulator 6 up to time tm when the accelerated calculation is completed. Figure 3 The actions described are the same, so the description is omitted.

[0059] Figure 4 The complete equipment model Mp shown is input to the control model Md of simulator 6 using the output data. The complete equipment model Mp generates input data for input into the control model Md of simulator 6 based on the output data. The complete equipment model Mp connects to (exchanges data with) the control model Md of simulator 6 according to the control operation cycle of the control model Md. For example... Figure 5 As shown, at time tm, simulator 6 begins simulation using input data generated by the complete equipment model Mp.

[0060] In addition, Figure 5 In the example shown, after time tm, the operation cycle of the control function Mc of the control device 4 and the operation cycle of the control model Md of the simulator 6 will become the same. Then, after time tm, that is, after the accelerated operation, if the operator operation control logic change unit 16 of the complete equipment 100 changes the control logic of the control model Md of the simulator 6, the output data comparison unit 18 compares the output data output from the control model Md of the simulator 6 and the output data output from the control function Mc of the control device 4 using the method described above.

[0061] Based on the aforementioned complete equipment operation simulation system 2 (2B), by confirming the impact of changes in the control logic of the control model Md of the simulator 6 on the input data generated by the complete equipment model Mp, it is possible to understand the impact of changes in the control logic of the control function Mc of the control device 4 on the output of the complete equipment 100. Therefore, it is possible to appropriately adjust the control logic of the control function of the control device 4 considering the input data generated by the complete equipment model Mp.

[0062] In addition, Figure 4 In the exemplary embodiment shown, the complete equipment model Mp is located inside the simulator 6. However, as long as the complete equipment model Mp can exchange input / output data with the control model Md of the simulator 6, it can also be located outside the simulator 6. When the simulator 6 is configured to include the complete equipment model Mp, and the complete equipment model Mp also has snapshot data and performs calculations synchronously with the control model Md, simulation can begin from the point when the snapshot is unfolded (the copying of the control calculation results begins) without needing to accelerate the calculation to catch up with the current operating state of the complete equipment. Furthermore, if the calculation is performed faster than the actual control calculation cycle, predictive calculations beyond the current point in time can also be performed.

[0063] Figure 6 This is a schematic structural diagram of a complete equipment operation simulation system 2 (2C) according to another embodiment.

[0064] Figure 6The control device 4 and simulator 6 of the complete equipment operation simulation system 2 (2C) shown are partly related to... Figure 1 The complete equipment operation simulation system 2(2A) shown is different, but its other basic structure is the same as that of the complete equipment operation simulation system 2(2A). Figure 6 Unless otherwise specified, the complete equipment operation simulation system 2 (2C) involved in the illustrated embodiment is considered to be related to... Figure 1 The symbols used in the complete equipment operation simulation system 2 (2A) shown are identical to those used in other systems. Figure 1 The complete equipment operation simulation system 2 (2A) shown has the same structure for all components, and descriptions are omitted. Furthermore, unless otherwise specified, the following should be used: Figure 7 The operation of the control device 4 and the simulator 6 described herein is also related to their use. Figure 3 The actions described are the same, so the description is omitted.

[0065] In the complete equipment operation simulation system 2 (2C), the control device 4 assigns a timestamp to the received data other than input data from the complete equipment 100 and transmits it to the simulator 6. Specifically, for example, when the control device 4 receives an operation command for operating the complete equipment 100 from the human-machine interface 8, or when the control device 4 receives communication data from other external devices 20, the control device 4 assigns a timestamp to the received data (operation command from the human-machine interface 8 or communication data from other external devices 20) and transmits it to the simulator 6. At this time, the path for transmitting the received data from the control device 4 to the simulator 6 can be either the information communication network 10 or the control communication network 12.

[0066] The emulator 6 stores the received data from the control device 4 in its storage device (e.g., the emulator 6's HDD78), and during the execution of accelerated computation, reproduces the received data at the time indicated by the timestamp assigned to the received data. Figure 7In the example of the timing diagram shown, after time t1, simulator 6, similar to control device 4, imports input data from equipment 100, operation instructions from human-machine interface 8, and communication data from external device 20, and stores them in simulator 6's storage device. Then, simulator 6 uses the calculation results contained in snapshot Qn transmitted from control device 4 (the calculation results of control function Mc of control device 4 at time tn), the aforementioned input data with timestamps after time tn (the time represented by the timestamp assigned to snapshot Qn) (input data from equipment 100 stored in simulator 6's storage device), and the aforementioned received data (operation instructions from human-machine interface 8 and communication data from external device 20) stored in simulator 6's storage device to perform the aforementioned accelerated calculation from time t(n+N) to time tm.

[0067] According to the above-mentioned complete equipment operation simulation system 2 (2C), even if the control device 4 receives communication data from other external devices 20 or operation instructions from human-machine devices 8 during the process of replicating the operating state of the complete equipment 100 at a certain point in time (including the internal state of the control device 4) using the simulator 6, causing the control logic of the control function of the control device 4 to change, the operating state of the complete equipment 100 can still be replicated using the simulator 6.

[0068] Figure 7 This is a timing diagram illustrating another example of the method for reproducing the operating state of the complete set of equipment 100 using the simulator 6, for the aforementioned complete set of equipment operation simulation system 2 (2A). Figure 3 The timing diagram shown is a variation.

[0069] exist Figure 7 The timing diagram shows the operation and use of the control device 4 and the simulator 6 up to time tm when the accelerated calculation is completed. Figure 3 The actions described are the same, so the description is omitted.

[0070] exist Figure 7In the example shown, after the simulator 6 starts simulating at time tm, step S12 and the saving of snapshot data in the simulator 6, as well as the saving of input data input from the equipment 100 via the input / output module 14, are repeatedly performed. Just before the accelerated calculation begins, the snapshot saved in step S12 and the input data saved during the snapshot saving interval (input data input via the input / output module 14) are reproduced (this reproduction is set as step S14). Steps S14 and S13 are then performed. Steps S14 and S13 can be repeated, and the result of step S13 can be saved in the simulator 6 as reproduction data for investigating the cause of the trip. The simulator 6 is configured to perform accelerated calculations using each snapshot stored in the simulator 6's storage device, and to save the calculation results (intermediate values ​​of the calculations of the control function Mc) contained in each snapshot transmitted from the control device 4 and the calculation results of the accelerated calculations in step S13 to the simulator 6's storage device (e.g., the simulator 6's HDD78, etc.).

[0071] Therefore, the calculation results of the control function Mc of the control device 4 and the results of the accelerated calculation can be sequentially saved to the simulator 6. Thus, in the event of a trip in the complete equipment 100, the snapshot stored in the storage device of the simulator 6 can be used to confirm the past calculation state in the control device 4, thereby enabling the investigation of the cause of the trip.

[0072] The present invention is not limited to the above-described embodiments, but also includes modifications to the above-described embodiments or appropriate combinations thereof.

[0073] The contents described in the above embodiments can be understood, for example, as follows.

[0074] (1) The complete equipment operation simulation system according to at least one embodiment of the present invention comprises:

[0075] A control device (e.g., control device 4 described above) has a control function (e.g., control function Mc described above), which outputs output data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment; and

[0076] The simulator (e.g., simulator 6 described above) includes a control model (e.g., control model Md described above) that simulates the control function of the control device, and is time-synchronized with the control device.

[0077] The control device and the simulator receive the input data at the same period for both the control device and the simulator.

[0078] The simulator assigns a timestamp to the input data it receives and stores it in a storage device.

[0079] The control device assigns a timestamp to a snapshot (e.g., snapshot Qn) of the calculation result of the control function of the control device at any time (e.g., time tn mentioned above), and transmits the snapshot to the simulator.

[0080] The simulator uses the calculation results contained in the snapshot transmitted from the control device and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, to perform accelerated calculations until it catches up with the current calculation time of the control function of the control device. The accelerated calculations perform the calculations of the simulator's control model at a cycle faster than the calculation cycle of the control function of the control device.

[0081] In the complete equipment operation simulation system described in (1) above, the simulator of the control model, which is time-synchronized with the control device and has a simulated control function, uses the calculation result (intermediate value of the control function's calculation) at a certain point in time contained in the snapshot transmitted from the control device and the input data with a timestamp after the time represented by the timestamp assigned to the snapshot to perform accelerated calculation until it catches up with the current calculation time of the control function of the control device. The accelerated calculation is performed by the simulator's control model at a cycle faster than the calculation cycle of the control function of the control device. Therefore, the operating state of the complete equipment at a certain point in time can be reproduced by a simulator different from the control device. Therefore, if the control logic of the control device is changed from this state, the simulator can be used during the operation of the complete equipment to confirm the impact of the change in control logic on the output value of the control device (e.g., whether the output value of the control device changes abruptly). Therefore, the risk of the controlled object of the complete equipment stopping suddenly or an unexpected accident occurring can be reduced.

[0082] (2) In some embodiments, in the complete equipment operation simulation system described in (1) above,

[0083] The simulator uses the calculation results contained in the snapshot transmitted from the control device as the initial value for the accelerated calculation.

[0084] According to the complete equipment operation simulation system described in (2) above, by using the calculation results of the control device contained in the snapshot as the initial value for accelerated calculation, the operating state of the complete equipment can be appropriately reproduced by the simulator.

[0085] (3) In some embodiments, in the complete equipment operation simulation system described in (1) or (2) above,

[0086] The control device divides the snapshot into multiple data points and transmits the multiple data points to the simulator through multiple operation cycles (e.g., the aforementioned N operation cycles).

[0087] According to the complete equipment operation simulation system described in (3) above, compared with the case where a snapshot is transmitted to the simulator in only one operation cycle, the increase in load caused by transmission in the control device can be suppressed.

[0088] (4) In some embodiments, the complete equipment operation simulation system described in any one of (1) to (3) above further includes an output data comparison unit (for example, the output data comparison unit 18 described above).

[0089] When the control logic of the simulator's control model is changed after the accelerated calculation, the output data comparison unit compares the output data output from the simulator's control model with the output data output from the control function of the control device.

[0090] According to the complete equipment operation simulation system described in (4) above, by changing the control logic of the simulator's control model after accelerated calculation, it is possible to confirm whether there is a significant difference between the output data output from the simulator's control model and the output data output from the control function of the control device (whether the output data changes abruptly).

[0091] (5) In some embodiments, in any one of (1) to (4) above, the complete equipment operation simulation system has a complete equipment model inside or outside the simulator.

[0092] The complete equipment model is a complete equipment model that simulates the complete equipment (e.g., the complete equipment model Mp mentioned above), and input data for inputting into the control model of the simulator is generated based on the output data of the control model of the simulator.

[0093] Based on the complete equipment operation simulation system described in (5) above, by confirming the impact of changes in the control logic of the simulator's control model on the input data generated by the complete equipment model, it is possible to understand the impact of changes in the control logic of the control device's control function on the output of the complete equipment. Therefore, it is possible to appropriately adjust the control logic of the control device's control function based on the input data generated by the complete equipment model.

[0094] (6) In some embodiments, in the complete equipment operation simulation system described in any one of (1) to (5) above,

[0095] The control device assigns a timestamp to the received data other than the input data (e.g., operation instructions from the human-machine interface 8 or communication data from the external device 20) and transmits it to the simulator.

[0096] The simulator stores the received data received from the control device in the storage device, and reproduces the received data at the time indicated by the timestamp assigned to the received data during the execution of the accelerated calculation.

[0097] According to the complete equipment operation simulation system described in (6) above, even if the control device receives communication data from other devices or operation instructions from human-machine devices during the process of replicating the operating state of the complete equipment at a certain point in time (including the internal state of the control device) using the simulator, causing the state of the control logic of the control function of the control device to change, the operating state of the complete equipment can still be replicated using the simulator.

[0098] (7) In some embodiments, in the complete equipment operation simulation system described in any one of (1) to (6) above,

[0099] The control device repeatedly performs multiple actions, including assigning timestamps to snapshots of the calculation results of the control function of the control device and transmitting the timestamped snapshots to the simulator.

[0100] The emulator stores each of the snapshots transmitted from the control device in the storage device (e.g., the HDD78 mentioned above).

[0101] According to the complete equipment operation simulation system described in (7) above, the calculation results of the control function of the control device can be saved sequentially to the simulator. Therefore, in the event of a trip in the complete equipment, the snapshot stored in the storage device can be used to confirm the past calculation state of the control device, thereby enabling the investigation of the cause of the trip.

[0102] (8) The complete equipment operation simulation method according to at least one embodiment of the present invention uses a control device (e.g., the control device 4 described above) and a simulator (e.g., the simulator 6 described above).

[0103] The control device has a control function (e.g., the aforementioned control function Mc), which outputs output data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment.

[0104] The simulator includes a control model (e.g., the aforementioned control model Md) that simulates the control functions of the control device, and is time-synchronized with the control device.

[0105] The complete set of equipment operation simulation method includes the following steps:

[0106] The control device and the simulator receive the input data at the same period for both the control device and the simulator;

[0107] The input data received by the simulator is timestamped and saved.

[0108] A snapshot (e.g., snapshot Qn) of the calculation results of the control function of the control device at any time (e.g., time tn mentioned above) is timestamped, and the snapshot is transmitted to the simulator; and

[0109] The accelerated computation is performed using the computation results contained in the snapshot and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, until it catches up with the current computation time of the control function of the control device. The accelerated computation performs the computation of the simulator's control model at a cycle faster than the computation cycle of the control function of the control device.

[0110] According to the complete equipment operation simulation system described in (8) above, the simulator of the control model, which is time-synchronized with the control device and has a simulated control function, uses the calculation result (intermediate value of the control function's calculation) at a certain point in time contained in the snapshot transmitted from the control device and the input data with a timestamp after the time represented by the timestamp assigned to the snapshot to perform accelerated calculation until it catches up with the current calculation time of the control function of the control device. The accelerated calculation is performed by the simulator's control model at a cycle faster than the calculation cycle of the control function of the control device. Therefore, the operating state of the complete equipment at a certain point in time can be reproduced by a simulator different from the control device. Therefore, if the control logic of the control device is changed from this state, the simulator can be used during the operation of the complete equipment to confirm the impact of the change in control logic on the output value of the control device (e.g., whether the output value of the control device changes abruptly). Therefore, the risk of the controlled object of the complete equipment stopping suddenly or an unexpected accident occurring can be reduced.

[0111] Symbol Explanation

[0112] 2-Complete equipment operation simulation system, 4-Control device, 6-Emulator, 8-Human machine device, 10-Information communication network, 12-Control communication network, 14-Input / output module, 16-Control logic change unit, 18-Output data comparison unit, 20-External device, 72-Processor, 74-RAM, 76-ROM, 78-HDD, 80-Input I / F, 82-Output I / F, 84-Bus, 100-Complete equipment, Mc-Control function, Md-Control model, Mp-Complete equipment model, Qn-Snapshot.

Claims

1. A complete set of equipment operation simulation system, comprising: A control device having a control function, wherein the control function outputs output data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment; and The simulator includes a control model that simulates the control functions of the control device and is time-synchronized with the control device. The control device and the simulator receive the input data at the same period for both the control device and the simulator. The simulator assigns a timestamp to the input data it receives and stores it in a storage device. The control device assigns a timestamp to a snapshot of the calculation results of the control function at any given time, and transmits the snapshot to the simulator. The simulator uses the calculation results contained in the snapshot transmitted from the control device and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, to perform accelerated calculations until it catches up with the current calculation time of the control function of the control device. The accelerated calculations perform the calculations of the simulator's control model at a cycle faster than the calculation cycle of the control function of the control device.

2. The complete set of equipment operation simulation system according to claim 1, wherein, The simulator uses the calculation results contained in the snapshot transmitted from the control device as the initial value for the accelerated calculation.

3. The complete set of equipment operation simulation system according to claim 1, wherein, The control device divides the snapshot into multiple data points and transmits the multiple data points to the simulator after multiple operation cycles.

4. The complete set of equipment operation simulation system according to claim 1, further comprising an output data comparison unit, When the control logic of the simulator's control model is changed after the accelerated calculation, the output data comparison unit compares the output data output from the simulator's control model with the output data output from the control function of the control device.

5. The complete equipment operation simulation system according to claim 1, wherein the simulator contains a complete equipment model inside or outside the simulator. The complete equipment model is a complete equipment model that simulates the complete equipment, and the input data for inputting into the control model of the simulator is generated based on the output data of the control model of the simulator.

6. The complete set of equipment operation simulation system according to claim 1, wherein, The control device assigns a timestamp to the received data other than the input data received by the control device, and transmits it to the simulator. The simulator stores the received data received from the control device in the storage device, and reproduces the received data at the time indicated by the timestamp assigned to the received data during the execution of the accelerated calculation.

7. The complete set of equipment operation simulation system according to claim 1, wherein, The control device repeatedly performs actions including assigning timestamps to snapshots of the calculation results of the control function of the control device and transmitting the timestamped snapshots to the simulator. The simulator stores each of the snapshots transmitted from the control device in the storage device.

8. A method for simulating the operation of a complete set of equipment, which uses a control device and a simulator. The control device has a control function, which outputs control data for controlling the complete set of equipment by inputting input data related to the state variables of the complete set of equipment. The simulator includes a control model that simulates the control functions of the control device and is time-synchronized with the control device. The complete set of equipment operation simulation method includes the following steps: The control device and the simulator receive the input data at the same period for both the control device and the simulator; The input data received by the simulator is timestamped and saved. A snapshot of the calculation result of the control function of the control device at any time is timestamped, and the snapshot is transmitted to the simulator; and The accelerated computation is performed using the computation results contained in the snapshot and the input data, which is a timestamp after the time represented by the timestamp assigned to the snapshot, until it catches up with the current computation time of the control function of the control device. The accelerated computation performs the computation of the simulator's control model at a cycle faster than the computation cycle of the control function of the control device.

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