A control parameter self-migration and verification system in chemical synthesis production line replication
By automating the extraction and intelligent adaptation of control parameters for chemical synthesis production lines, the problem of control instability caused by hardware differences in production line replication has been solved, achieving efficient and safe production line migration and quality assurance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- NINGBO XINGBOYUAN INTELLIGENT TECHNOLOGY CO LTD
- Filing Date
- 2026-03-31
- Publication Date
- 2026-06-30
AI Technical Summary
In the fields of chemical pharmaceuticals and fine chemicals, existing technologies lack automated parameter extraction mechanisms during production line replication, cannot handle hardware differences, lack adaptive parameter mapping models, and lack effective pre-verification methods, resulting in unstable control performance and safety risks.
The system employs a parameter extraction module to automatically acquire control parameters, a hardware difference analysis module to generate adaptation parameters, a digital twin verification module for simulation verification, and a batch download and tracking verification module for consistency evaluation, thereby forming a reusable process knowledge base.
It enables automated extraction and intelligent adaptation of control parameters, reduces the production line replication cycle, ensures control performance and product quality stability, and avoids trial-and-error costs and safety hazards.
Abstract
Description
Technical Field
[0001] This invention relates to the field of industrial automation control technology, and more specifically, to a self-migrating and verification system for control parameters in the replication of a chemical synthesis production line. Background Technology
[0002] In the fields of chemical pharmaceuticals and fine chemicals, companies often need to replicate proven and mature production processes from one production line to a new one to expand capacity or optimize production layout. Currently, production line replication typically employs two technical approaches: First, automation engineers rewrite or debug the PLC control program on the new production line. This process is highly dependent on personal experience and can take weeks or even months, severely limiting the speed of capacity expansion. Second, parameter replication involves exporting the control parameter table from the source production line and manually adjusting it before inputting it into the new PLC. However, due to differences in hardware configurations such as sensor range, actuator response time, and reactor volume, directly replicating parameters often leads to problems such as control overshoot and slow response, and may even result in raw material waste or equipment damage.
[0003] While existing technologies include model-based transition control, demand-capacity matching, and parameter pre-verification, they all have significant drawbacks. First, they lack automated mechanisms for extracting source production line parameters, relying heavily on manual extraction, which is inefficient and prone to errors. Second, existing parameter switching technologies are mostly designed for the same hardware platform, failing to handle the impact of hardware differences on control parameters and lacking adaptive parameter mapping models. Third, there is a lack of effective pre-verification methods after parameter migration, often requiring actual material input and trial runs, which poses safety risks. Finally, the lack of a quantitative consistency assessment mechanism after replication makes it difficult to guarantee product quality stability. Therefore, a comprehensive solution capable of automating control parameter extraction, intelligent adaptation, pre-verification, and tracking evaluation is urgently needed. Summary of the Invention
[0004] To address the aforementioned technical problems in related technologies, this invention proposes a self-migrating and verification system for control parameters in the replication of chemical synthesis production lines, which can overcome the above-mentioned shortcomings of existing technologies.
[0005] To achieve the above-mentioned technical objectives, the technical solution of the present invention is implemented as follows: A self-migrating and verification system for control parameters in the replication of a chemical synthesis production line; The self-migrating and verification system for control parameters in the replication of this chemical synthesis production line includes: The parameter extraction module is used to extract control parameters from the source production line PLC and construct the source parameter set; The hardware difference analysis module is used to compare the hardware configuration differences between the source production line and the target production line and generate hardware difference information. The parameter mapping model module is used to adjust the parameters in the source parameter set according to the hardware difference information to generate a target parameter set that is adapted to the target production line. The digital twin verification module is used to run the target parameter set in a virtual environment and perform simulation verification on the target parameter set; The batch download and tracking verification module is used to write the verified target parameter set into the target production line PLC, and collect the running data and perform consistency evaluation with the historical data of the source production line when the target production line is running.
[0006] Furthermore, the parameter extraction module communicates with the source production line PLC via an industrial communication protocol, and the extracted control parameters include PID parameters, timing parameters, alarm thresholds, interlocking conditions, and recipe parameters.
[0007] Furthermore, the hardware configurations compared by the hardware difference analysis module include sensor range, actuator response time, reactor volume, and heat exchanger area; the hardware difference analysis module is used to construct a hardware difference matrix, and the elements in the hardware difference matrix are used to represent the difference coefficients between the target production line and the source production line on the same hardware attribute.
[0008] Furthermore, the parameter mapping model module adopts a rule-based adaptive mapping algorithm, which includes: adjusting PID parameters according to sensor range differences, adjusting timing parameters according to reactor volume differences, and increasing compensation waiting time according to actuator response time differences.
[0009] Furthermore, the parameter mapping model module also includes a parameter optimization submodule based on reinforcement learning. The parameter optimization submodule is used to receive the consistency evaluation results fed back by the batch download and tracking verification module, and optimize the parameter mapping strategy according to the consistency evaluation results.
[0010] Furthermore, the digital twin verification module includes: Virtual reactor models are used to simulate chemical synthesis processes. A virtual controller model used to run the same control logic as the target PLC; A simulation engine is used to perform closed-loop simulations of the virtual reactor model and the virtual controller model; Anomaly detectors are used to identify abnormal phenomena during the simulation process.
[0011] Furthermore, the digital twin verification module also includes a parameter hardening submodule, which is used to generate soft protection logic according to the abnormality pattern when the anomaly detector identifies an anomaly, and to combine the soft protection logic with the adjusted target parameter set to form a hardened target parameter package.
[0012] Furthermore, the batch download and tracking verification module is used to calculate the consistency index C, which is used to quantify the degree of matching between the target production line operation data and the source production line historical data.
[0013] Furthermore, the batch download and tracking verification module is also used to issue an early warning when the consistency index C is lower than a preset threshold, and to feed back the consistency index C to the parameter mapping model module for optimizing the parameter mapping strategy.
[0014] Furthermore, the batch download and tracking verification module is also used to write the verified target parameter set into the target production line PLC through the industrial communication protocol, and to verify the integrity of the written data.
[0015] The beneficial effects of this invention are as follows: The parameter extraction module automatically obtains control parameters from the source production line PLC, avoiding the inefficiency and error-prone nature of manual extraction; the hardware difference analysis module and parameter mapping model module automatically generate parameters adapted to the target production line based on hardware differences, solving the problem of parameter failure caused by different hardware configurations; the digital twin verification module completes simulation verification before material feeding, identifying parameter conflicts and potential risks in advance, avoiding trial-and-error costs and safety hazards; the batch download and tracking verification module enables rapid parameter deployment and consistency evaluation after replication, thereby significantly shortening the production line replication cycle, lowering the technical threshold, ensuring the control performance and product quality stability after replication, and forming a reusable process knowledge base. Detailed Implementation
[0016] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.
[0017] A self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to an embodiment of the present invention includes: The parameter extraction module is used to extract control parameters from the source production line PLC and construct the source parameter set; The hardware difference analysis module is used to compare the hardware configuration differences between the source production line and the target production line and generate hardware difference information. The parameter mapping model module is used to adjust the parameters in the source parameter set according to the hardware difference information to generate a target parameter set that is adapted to the target production line. The digital twin verification module is used to run the target parameter set in a virtual environment and perform simulation verification on the target parameter set; The batch download and tracking verification module is used to write the verified target parameter set into the target production line PLC, and collect the running data and perform consistency evaluation with the historical data of the source production line when the target production line is running.
[0018] According to the control parameter self-migration and verification system for replicating a chemical synthesis production line of the present invention, in a specific embodiment, the parameter extraction module communicates with the source production line PLC through an industrial communication protocol, and the extracted control parameters include PID parameters, timing parameters, alarm thresholds, interlocking conditions, and formula parameters.
[0019] According to the self-migration and verification system for control parameters in the replication of a chemical synthesis production line of the present invention, in a specific embodiment, the hardware configuration compared by the hardware difference analysis module includes sensor range, actuator response time, reactor volume, and heat exchanger area; the hardware difference analysis module is used to construct a hardware difference matrix, and the elements in the hardware difference matrix are used to represent the difference coefficient between the target production line and the source production line on the same hardware attribute.
[0020] According to the present invention, in a specific embodiment of the control parameter self-transfer and verification system for replicating a chemical synthesis production line, the parameter mapping model module adopts a rule-based adaptive mapping algorithm, which includes: adjusting PID parameters according to sensor range differences, adjusting timing parameters according to reactor volume differences, and increasing compensation waiting time according to actuator response time differences.
[0021] In a specific embodiment of the self-transfer and verification system for control parameters in the replication of a chemical synthesis production line according to the present invention, the parameter mapping model module further includes a parameter optimization submodule based on reinforcement learning. The parameter optimization submodule is used to receive the consistency evaluation results fed back by the batch download and tracking verification module, and optimize the parameter mapping strategy according to the consistency evaluation results.
[0022] According to the self-migrating and verification system for control parameters in the replication of a chemical synthesis production line of the present invention, in a specific embodiment, the digital twin verification module includes: Virtual reactor models are used to simulate chemical synthesis processes. A virtual controller model used to run the same control logic as the target PLC; A simulation engine is used to perform closed-loop simulations of the virtual reactor model and the virtual controller model; Anomaly detectors are used to identify abnormal phenomena during the simulation process.
[0023] According to the present invention, in a specific embodiment of the control parameter self-migration and verification system for replicating a chemical synthesis production line, the digital twin verification module further includes a parameter hardening submodule. The parameter hardening submodule is used to generate soft protection logic according to the abnormality pattern when the abnormality detector identifies an abnormality, and to combine the soft protection logic with the adjusted target parameter set to form a hardened target parameter package.
[0024] According to the self-migration and verification system for control parameters in the replication of a chemical synthesis production line of the present invention, in a specific embodiment, the batch download and tracking verification module is used to calculate the consistency index C, which is used to quantify the degree of matching between the target production line operation data and the source production line historical data.
[0025] In a specific embodiment of the control parameter self-migration and verification system for replicating a chemical synthesis production line according to the present invention, the batch download and tracking verification module is further used to issue an early warning when the consistency index C is lower than a preset threshold, and to feed back the consistency index C to the parameter mapping model module for optimizing the parameter mapping strategy.
[0026] In a specific embodiment of the control parameter self-migration and verification system for replicating a chemical synthesis production line according to the present invention, the batch download and tracking verification module is further used to write the verified target parameter set into the target production line PLC through an industrial communication protocol, and verify the integrity of the written data.
[0027] To facilitate understanding of the above technical solutions of the present invention, the following detailed description of the above technical solutions of the present invention will be provided through specific usage methods.
[0028] In practical use, the self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to the present invention includes the following modules: (1) Parameter extraction module The parameter extraction module is used to read all control parameters, process recipes and timing logic from the source production line PLC through industrial communication protocols, and construct a structured "source parameter set".
[0029] Specifically, the parameter extraction module communicates with the source production line PLC via OPC UA, Modbus TCP, or PROFINET protocols. The extracted parameters include, but are not limited to: the proportional coefficient Kp, integral time Ti, and derivative time Td of the PID controller; the timing delay parameters of each phase; temperature / pressure alarm thresholds; interlock protection conditions; and the feeding rate, reaction time, and stirring speed in the formula.
[0030] (2) Hardware Difference Analysis Module The hardware difference analysis module is used to compare the hardware configuration differences between the source production line and the target production line, and generate hardware difference information. The hardware configuration includes sensor model and range, actuator response time, reactor volume, and heat exchanger area.
[0031] In this embodiment, the hardware difference analysis module constructs a hardware difference matrix D, where the element d_ij represents the difference coefficient of the i-th hardware on the j-th attribute, and the calculation formula is: d_ij = (T_ij - S_ij) / S_ij Where S_ij is the hardware attribute value of the source production line, and T_ij is the hardware attribute value of the target production line.
[0032] (3) Parameter mapping model module The parameter mapping model module is used to adjust the parameters in the source parameter set based on the hardware difference information to generate a "target parameter set" that is adapted to the target production line.
[0033] Specifically, the parameter mapping model module employs a rule-based adaptive mapping algorithm, including: For PID parameters, scaling is applied based on the sensor range differences: Kp_target = Kp_source * (range_source / range_target) Ti_target = Ti_source Td_target = Td_source For timing parameters, adjustments are made based on the differences in reactor volume: t_add_target = t_add_source * (V_target / V_source) t_hold_target = t_hold_source To compensate for the difference in actuator response time, add a waiting time: t_wait_target = t_wait_source + (resp_target - resp_source) Furthermore, the parameter mapping model module also includes a reinforcement learning-based parameter optimization submodule. This submodule receives the consistency evaluation results from the batch download and tracking verification module and optimizes the parameter mapping strategy based on these results. Specifically, this submodule forms a closed-loop feedback with the tracking verification module: after each copy is completed, the consistency index C calculated by the tracking verification module is fed back to the parameter optimization submodule as a reward signal in real time; if C is higher than a preset threshold (e.g., 0.95), the mapping strategy is positively reinforced; if C is lower than the preset threshold, the weight parameters within the mapping model are adjusted in reverse. Through this online learning mechanism, the system can continuously optimize parameter mapping accuracy without accumulating a large number of cases, achieving an adaptive capability that becomes more accurate with use.
[0034] (4) Digital twin verification module The digital twin verification module is used to run the target parameter set in a virtual environment, perform simulation verification on the target parameter set, and identify parameter conflicts or potential risks.
[0035] The digital twin verification module includes: The virtual reactor model includes reaction kinetics equations, heat transfer equations, and material balance equations. The virtual controller model runs the same control logic as the target PLC and receives the target parameter set; The simulation engine is used to perform closed-loop simulations of virtual reactors and virtual controllers. Anomaly detectors are used to identify abnormal phenomena such as overshoot, oscillation, and exceeding limits that occur during the simulation process; The parameter hardening submodule automatically generates soft protection logic based on the abnormality mode when the anomaly detector identifies a potential risk. This includes, but is not limited to, functional blocks such as adaptive feedforward compensation, setpoint step limit, and output rate limit. The generated protection logic code is then combined with the adjusted target parameter set to form a hardened target parameter package. A verification report generator is used to output parameter verification results and potential risk warnings.
[0036] (5) Batch download and tracking verification module The batch download and tracking verification module is used to write the verified target parameter set into the target production line PLC, and collect the running data and perform consistency evaluation with the historical data of the source production line when the target production line is running.
[0037] Specifically, the batch download module receives the hardened target parameter package from the digital twin verification module, writes the parameter set and the newly added protection logic code into the target production line PLC through the industrial communication protocol, and automatically verifies the integrity of the written data.
[0038] During the initial run, the batch download and tracking verification module collects real-time operational data from the target production line, compares it with historical data from the source production line, and calculates the consistency index C. C = 1 - (1 / n) * Σ |(x_target_i - x_source_i) / x_source_i| Where x_target_i is the actual value of the i-th key indicator of the target production line, and x_source_i is the mean value of the corresponding indicator of the source production line. When C is lower than the preset threshold, the system automatically issues an early warning and prompts for re-verification; at the same time, the value of C is fed back to the reinforcement learning submodule of the parameter mapping model module in real time as a reward signal for online model updates.
[0039] In summary, by utilizing the technical solutions described above, the parameter extraction module automatically obtains control parameters from the source production line PLC, avoiding the inefficiency and error-prone nature of manual extraction. The hardware difference analysis module and parameter mapping model module automatically generate parameters adapted to the target production line based on hardware differences, resolving parameter failure issues caused by different hardware configurations. The digital twin verification module performs simulation verification before material input, identifying parameter conflicts and potential risks in advance, avoiding trial-and-error costs and safety hazards. The batch download and tracking verification module enables rapid parameter deployment and consistency evaluation after replication, thereby significantly shortening the production line replication cycle, lowering the technical threshold, ensuring control performance and product quality stability after replication, and forming a reusable process knowledge base.
[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A self-migrating and verification system for control parameters in the replication of a chemical synthesis production line, characterized in that, include: The parameter extraction module is used to extract control parameters from the source production line PLC and construct the source parameter set; The hardware difference analysis module is used to compare the hardware configuration differences between the source production line and the target production line and generate hardware difference information. The parameter mapping model module is used to adjust the parameters in the source parameter set according to the hardware difference information to generate a target parameter set that is adapted to the target production line. The digital twin verification module is used to run the target parameter set in a virtual environment and perform simulation verification on the target parameter set; The batch download and tracking verification module is used to write the verified target parameter set into the target production line PLC, and collect the running data and perform consistency evaluation with the historical data of the source production line when the target production line is running.
2. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The parameter extraction module communicates with the source production line PLC through an industrial communication protocol, and the extracted control parameters include PID parameters, timing parameters, alarm thresholds, interlocking conditions, and recipe parameters.
3. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The hardware configurations compared by the hardware difference analysis module include sensor range, actuator response time, reactor volume, and heat exchanger area. The hardware difference analysis module is used to construct a hardware difference matrix, and the elements in the hardware difference matrix are used to represent the difference coefficients between the target production line and the source production line on the same hardware attribute.
4. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The parameter mapping model module adopts a rule-based adaptive mapping algorithm, which includes: adjusting PID parameters according to sensor range differences, adjusting timing parameters according to reactor volume differences, and increasing compensation waiting time according to actuator response time differences.
5. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The parameter mapping model module also includes a parameter optimization submodule based on reinforcement learning. The parameter optimization submodule is used to receive the consistency evaluation results fed back by the batch download and tracking verification module, and optimize the parameter mapping strategy according to the consistency evaluation results.
6. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The digital twin verification module includes: Virtual reactor models are used to simulate chemical synthesis processes. A virtual controller model used to run the same control logic as the target PLC; A simulation engine is used to perform closed-loop simulations of the virtual reactor model and the virtual controller model; Anomaly detectors are used to identify abnormal phenomena during the simulation process.
7. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 6, characterized in that, The digital twin verification module also includes a parameter hardening submodule, which is used to generate soft protection logic according to the abnormality pattern when the anomaly detector identifies an anomaly, and to combine the soft protection logic with the adjusted target parameter set to form a hardened target parameter package.
8. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The batch download and tracking verification module is used to calculate the consistency index C, which is used to quantify the degree of matching between the target production line operation data and the source production line historical data.
9. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 8, characterized in that, The batch download and tracking verification module is also used to issue an early warning when the consistency index C is lower than a preset threshold, and to feed back the consistency index C to the parameter mapping model module for optimizing the parameter mapping strategy.
10. The self-migrating and verification system for control parameters in the replication of a chemical synthesis production line according to claim 1, characterized in that, The batch download and tracking verification module is also used to write the verified target parameter set into the target production line PLC through the industrial communication protocol, and to verify the integrity of the written data.