Material batch control whole-process simulation system and method and storage medium

Abstract

The application discloses a material batch control whole-process simulation system and method and a storage medium, wherein the material batch control whole-process simulation system comprises a batch control system configured to send a formula parameter corresponding to a current formula stage to a process control system; the process control system is further configured to map the formula parameter to a virtual control system through a first data transmission link of a communication bridge; the virtual control system is configured to generate a control instruction according to the formula parameter, send the control instruction to a digital twin system, receive a virtual equipment state signal fed back by the digital twin system through a second data interaction link of the communication bridge, and map the virtual equipment state signal to the process control system through the first data transmission link, so that the process control system sends the virtual equipment state signal to the batch control system, and the batch control system completes whole-process data penetration verification according to the virtual equipment state signal.

Description

Technical Field

[0001] This invention relates to the field of industrial automation technology, specifically to a batch control full-process simulation system, method, and storage medium. Background Technology

[0002] In the production of lithium-ion battery cathode materials, batch control involves multi-level coordination among the manufacturing execution system, batch scheduling system, and process control system. In related technologies, the industry primarily employs standardized formulation models to control the flow of process control elements in such batch control systems (e.g., following batch control standards such as ISA-88).

[0003] However, most virtual commissioning solutions in related technologies are limited to pure logic verification of the underlying controller or status monitoring of individual devices. The process parameters determined by the batch control system based on the formula cannot be automatically sent to the digital twin model to drive the equipment to execute. Similarly, the virtual feedback signals generated by the digital twin model cannot be automatically sent back to the batch control system. Therefore, the data link between the business layer and the equipment layer is disconnected, making it impossible to achieve full-process data connectivity verification from the issuance of production plans to the execution of end devices. Summary of the Invention

[0004] The present invention aims to at least partially solve the aforementioned technical problems in related technologies. To this end, the present invention provides a material batch control full-process simulation system and method, a communication bridge for material batch control full-process simulation verification, and a computer-readable storage medium, to establish a bidirectional data link between the batch control system, process control system, virtual control system, and digital twin system, thereby achieving full-process data connectivity verification from material production formula issuance, formula stage and equipment stage collaboration, control command execution to virtual equipment status feedback.

[0005] The primary objective of this invention is to propose a full-process simulation system for batch control of materials.

[0006] The second objective of this invention is to propose a communication bridge for simulation verification of the entire process of material batch control.

[0007] The third objective of this invention is to propose a full-process simulation method for batch control of materials.

[0008] A fourth objective of this invention is to provide a computer-readable storage medium.

[0009] To achieve the above objectives, a material batch control full-process simulation system is proposed according to a first aspect of the present invention, comprising a batch control system, a process control system, a communication bridge, a virtual control system, and a digital twin system. The batch control system is connected to the process control system and is used to acquire the material production formula, determine the current formula stage based on the material production formula, and send the formula parameters corresponding to the current formula stage to the process control system; the process control system has multiple equipment stages pre-set, each corresponding to a formula stage. The communication bridge is used to establish a first data transmission link between the process control system and the virtual control system, and a second data interaction link between the virtual control system and the digital twin system; the process control system maps the formula parameters to the virtual control system through the first data transmission link. The virtual control system is connected to the digital twin system and is used to generate control commands based on the formula parameters and send them to the digital twin system, so that the digital twin system constructed based on the material production process executes the control commands; the virtual control system also receives virtual equipment status signals fed back by the digital twin system through the second data interaction link, and maps the virtual equipment status signals to the process control system through the first data transmission link, and the process control system sends the virtual equipment status signals to the batch control system, so that the batch control system completes full-process data connectivity verification based on the virtual equipment status signals.

[0010] According to an embodiment of the present invention, the material batch control full-process simulation system forms a closed loop through a first data transmission link and a second data interaction link, which sends formula parameters downwards and provides feedback on the virtual device status in the opposite direction. This enables the formula stage of the business layer, the device stage of the control layer, and the execution process of the virtual device in the digital twin system to be interconnected. As a result, the data transmission, control logic, and stage flow of the entire material batch control process can be verified without relying on the commissioning of a real production line.

[0011] According to one embodiment of the present invention, the communication bridge establishes communication connections between the process control system and the virtual control system through a virtual communication interface, and configures the data mapping relationship between the two to construct a first data transmission link; the communication bridge also configures an input-output signal mapping relationship between the virtual control system and the digital twin system to construct a second data interaction link, thereby realizing bidirectional transmission of recipe parameters, control commands and virtual device status information.

[0012] According to one embodiment of the present invention, the process control system includes a process control platform and a virtual controller. The process control platform is used to respond to the current recipe stage sent by the batch control system, and after the corresponding equipment stage is activated, to send the recipe parameters corresponding to the current recipe stage to the virtual controller; the virtual controller is used to write the recipe parameters into a first transmit data area, and according to the data mapping relationship established by the communication bridge, to transmit the recipe parameters in the first transmit data area to the first receive data area corresponding to the virtual control system.

[0013] According to one embodiment of the present invention, the virtual control system receives virtual device status information fed back by the digital twin system, writes the virtual device status information into the second transmission data area, and transmits the virtual device status information to the second reception data area corresponding to the process control system according to the data mapping relationship of the first data transmission link, so as to complete the reverse feedback of the virtual device status information.

[0014] According to one embodiment of the present invention, the virtual controller sends a communication status detection signal to the virtual control system at a preset period. If no response signal is received from the virtual control system within the preset period, it determines that there is a communication anomaly between the process control system and the virtual control system, controls the current equipment stage to maintain its current execution state, sends a communication anomaly alarm message to the batch control system, and controls the digital twin system to suspend the simulation execution of the current process. After communication is restored, the simulation verification of the corresponding process continues. This avoids stage state mismatch or simulation process disorder caused by communication anomalies.

[0015] According to one embodiment of the present invention, the digital twin system performs physical evolution calculations of the corresponding process according to control instructions, generates corresponding virtual device status information based on the physical evolution calculations, and writes the virtual device status information into the input data area of ​​the virtual control system according to the input-output signal mapping relationship established by the second data interaction link, so that the virtual control system can make process status judgments.

[0016] According to one embodiment of the present invention, the batch control system generates a control formula based on the material production formula, determines the current formula stage based on the control formula, activates the corresponding equipment stage in the process control system based on the current formula stage, and sends the formula parameters corresponding to the current formula stage to the process control system. Thus, the formula stage and the equipment stage operate in a coordinated manner according to a preset correspondence.

[0017] According to one embodiment of the present invention, the batch control system filters equipment entities that match the equipment type in the material production formula, then filters candidate equipment entities that are idle or ready based on their operating status, and determines the target equipment entity based on the rated capacity of the candidate equipment entities and the material requirements corresponding to the material production formula. Subsequently, the target equipment entity is assigned to the current control formula, and corresponding equipment identification information is generated. Thus, equipment selection and allocation consistent with actual batch production logic can be completed in a simulation environment.

[0018] According to one embodiment of the present invention, a digital twin system includes multiple digital twin models. Each digital twin model is established based on historical operating data and performs process simulation calculations according to model parameters. The digital twin model is driven by historical control commands and determined based on the consistency between the model calculation results and the corresponding historical process data, thereby enabling the digital twin model to characterize the dynamic response of the corresponding process.

[0019] According to one embodiment of the present invention, the digital twin model is verified by comparing the consistency between the model calculation results and historical process data; when the consistency meets the preset requirements, the corresponding model is used as the digital twin model; when the consistency does not meet the preset requirements, the model parameters are optimized, and the digital twin model is reconstructed based on the optimized model parameters.

[0020] Through the above model verification and parameter optimization mechanisms, the calculation results of the digital twin model can meet the preset consistency requirements, improve the ability of virtual equipment status information to represent the actual process, and provide reliable feedback for the simulation verification of batch control logic and the entire process data link.

[0021] According to one embodiment of the present invention, multiple digital twin models include a weighing and batching model, a motor dynamic response model, a cavity temperature extrapolation model, and a material evolution model, to respectively simulate the batching, motor response, temperature change, and material evolution processes in the material production process.

[0022] According to one embodiment of the present invention, the model parameters include feeding parameters, motor dynamic response parameters, thermal balance parameters, and material evolution parameters. These various model parameters are used to support the process simulation calculations of the corresponding digital twin models.

[0023] To achieve the above objectives, a communication bridge for full-process simulation verification of material batch control is proposed according to a second aspect of the present invention, comprising a communication connection module, a data mapping module, and a signal mapping module. The communication connection module establishes a data transmission link between the process control system and the virtual control system; the data mapping module configures the data mapping relationship between the process control system and the virtual control system to realize the data transmission of formula parameters and virtual equipment status information; the signal mapping module establishes the input / output signal mapping relationship between the virtual control system and the digital twin system to realize the interaction of control commands and virtual equipment status information. Through these modules, the communication bridge can connect control and simulation systems at different levels and in different operating environments, providing a unified data transmission and signal mapping channel for bidirectional data flow throughout the entire process.

[0024] To achieve the above objectives, a material batch control full-process simulation method is proposed according to a third aspect embodiment of the present invention, comprising: a batch control system acquiring a material production formula and generating a control formula based on the material production formula; the batch control system determining the current formula stage based on the control formula and generating corresponding formula parameters; a process control system activating the corresponding equipment stage based on the current formula stage and receiving the formula parameters; a communication bridge transmitting the formula parameters to a virtual control system via a first data transmission link; the virtual control system generating control instructions based on the formula parameters and sending the control instructions to a digital twin system; the digital twin system executing process simulation based on the control instructions and generating corresponding virtual equipment status information; the communication bridge feeding back the virtual equipment status information to the virtual control system via a second data interaction link; the virtual control system feeding back the virtual equipment status information to the process control system via the first data transmission link; the process control system sending the virtual equipment status information to the batch control system; and the batch control system determining whether the current formula stage is completed based on the virtual equipment status information and proceeding to the next formula stage, thereby achieving data connectivity verification of the entire material batch control process.

[0025] The material batch control full-process simulation method according to embodiments of the present invention, through the step-by-step issuance of formula parameters, simulation driven by control commands, step-by-step feedback of virtual equipment status, and cyclical advancement of the formula stage, can verify the complete closed loop from material production formula to execution by the end virtual equipment, and improve the verification completeness and reliability of the batch control program before actual operation.

[0026] To achieve the above objectives, a computer-readable storage medium is provided according to a fourth aspect embodiment of the present invention, on which a computer program is stored. When processed by a processor, the computer program executes the aforementioned material batch control full-process simulation method. Thus, data continuity verification of the aforementioned material batch control full-process can be implemented in the form of a computer program.

[0027] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of a material batch control full-process simulation system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of a material batch control full-process simulation system according to another embodiment of the present invention; Figure 3 This is a schematic diagram of the communication process between control systems with different architectures according to an embodiment of the present invention; Figure 4This is a flowchart illustrating a full-process simulation method for material batch control according to an embodiment of the present invention. Detailed Implementation

[0029] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0030] It should be noted that this invention is the result of the inventor's understanding and research into the following issues: In the production of lithium-ion battery cathode materials, batch control involves multi-level coordination among the manufacturing execution system, batch scheduling system, and process control system. In related technologies, the industry primarily employs standardized formulation models to control the flow of process control elements in such batch control systems (e.g., following batch control standards such as ISA-88).

[0031] However, during the verification phase before system deployment, the simulation systems in related technologies have the following shortcomings: 1. Virtual debugging in related technologies is mostly limited to the pure logic layer, with the entire data link being fragmented, making it impossible to achieve full-process data connectivity verification from production plan issuance and master formula analysis to end-device execution; 2. Difficulty in collaborative testing of heterogeneous control systems: Lithium battery production lines often contain heterogeneous control systems with different architectures (such as the process control system in the central control room and the virtual control system at the end). When testing cross-system data interaction, related technologies usually rely on actual hardware for joint debugging, which is time-consuming and costly. There is a lack of mechanisms to achieve real-time communication and collaborative operation of heterogeneous systems in a pure virtual environment without hardware. 3. Digital twins in related technologies lack deep integration with batch control logic: Related technologies focus on status monitoring and visualization of individual equipment, but lack deep integration with upper-level batch control logic (i.e., formula execution sequence). When program control elements dynamically switch, it is impossible to link and deduce material changes and dynamic mechanism responses of equipment in real time, making it difficult to achieve closed-loop verification of "control command - equipment response - process evolution - sensor feedback". 4. Lithium-ion battery cathode materials (such as ternary precursors and lithium salts) are expensive. The debugging methods in related technologies are highly dependent on the real physical environment and real materials to verify process parameters. Once there are defects in the formulation logic, it is very easy to cause serious material waste, equipment damage and safety risks.

[0032] Based on this, embodiments of the present invention provide a material batch control full-process simulation system, method, communication bridge for material batch control full-process simulation verification, and computer-readable storage medium to solve at least one of the above-mentioned technical problems.

[0033] The following description, with reference to the accompanying drawings, describes a material batch control full-process simulation system, method, communication bridge for material batch control full-process simulation verification, and computer-readable storage medium according to embodiments of the present invention.

[0034] It should be noted that the communication bridge described in this invention can establish a cross-platform data mapping channel between the process control system and the virtual control system, and an input / output signal mapping channel between the virtual control system and the digital twin system, based on a virtual communication interface and industrial communication protocols. The virtual communication interface can be composed of a virtual network adapter, a software coupling interface, or other interfaces capable of realizing virtual communication connections; the industrial communication protocol can include, but is not limited to, the S7 protocol, OPC UA, or Modbus TCP.

[0035] Figure 1 This is a system schematic diagram of a material batch control full-process simulation system according to an embodiment of the present invention. Figure 1 As shown, the material batch control full-process simulation system includes: batch control system 10, process control system 20, communication bridge 30, virtual control system 40, and digital twin system 50.

[0036] The batch control system 10 is connected to the process control system 20. The batch control system 10 acquires the material production formula, determines the current formula stage based on the formula, and sends the formula parameters corresponding to the current formula stage to the process control system 20. The process control system 20 presets multiple equipment stages, each corresponding one-to-one with a formula stage. The communication bridge 30 establishes a first data transmission link 31 between the process control system 20 and the virtual control system 40, and a second data interaction link 32 between the virtual control system 40 and the digital twin system 50. The process control system 20 maps the formula parameters to the virtual control system 40 through the first data transmission link 31. The virtual control system 40 is connected to the digital twin system 50 and is used to generate control commands based on the formula parameters and send the control commands to the digital twin system 50 so that the digital twin system 50, which is built based on the material production process, can execute the control commands. The virtual control system 40 also receives virtual device status signals fed back by the digital twin system 50 through the second data interaction link 32, and maps the virtual device status signals to the process control system 20 through the first data transmission link 31. The process control system 20 then sends the virtual device status signals to the batch control system 10 so that the batch control system 10 can complete the full-process data connection verification based on the virtual device status signals.

[0037] The material batch control full-process simulation system in this embodiment is built on the ISA-88 batch control standard architecture.

[0038] The batch control system 10 can be a batch scheduling engine running on the PCS7 (a process control system launched by Siemens) platform. Alternatively, it can be a customized state machine module that "hard-codes" the scheduling logic of the lithium battery cathode formula directly on the PCS7 platform using a high-level programming language (such as SCL) or a graph (SFC state diagram). The upper-level control system can then directly write the formula ratio and process parameters into this state machine module to complete the instruction distribution.

[0039] The batch control system 10 receives material production formulas from the upper-level control system. The upper-level control system can be a manufacturing execution system (MAS). The MAS establishes a data interface with the batch control system 10, receiving the material production formulas through this interface. Alternatively, it can use general spreadsheet software (such as Excel combined with VBA macros) or script files (such as XML or JSON format formula sheets). After parsing by middleware, the formulas are periodically written into the input registers of the batch control system 10 to complete the business-driven process. The material production formula, also known as the master formula, includes the production plan and various parameters for lithium battery materials. The batch control system 10 parses the material production formula to determine the current formula stage and the corresponding formula parameters. The batch control system 10 then sends the formula parameters to the process control system 20 via a standardized communication protocol.

[0040] The process control system 20 coordinates the overall sequential logic of process operations based on the formula parameters, while the virtual control system 40 converts the formula parameters into specific control commands and outputs them to the digital twin system 50. In some application scenarios, the process control system 20 and the virtual control system 40 adopt different control architectures. For example, the process control system 20 uses a PCS 7 architecture, while the virtual control system 40 uses a PLCSIM Advanced architecture. The two interact through a first data transmission link 31 constructed by a communication bridge 30. The communication bridge 30 can be deployed with a cross-platform virtual gateway or software coupling interface to transmit formula parameters, handshake signals, safety interlock information, and virtual device status information.

[0041] After receiving the formula parameters from the batch control system 10, the process control system 20 sends the formula parameters to the virtual control system 40 through the first data transmission link 31. The virtual control system 40 generates control commands based on the formula parameters and sends the control commands to the digital twin system 50. The control commands are used for complete and accurate execution-level sequential control logic.

[0042] The digital twin system 50 includes a digital twin model covering the entire mixing process built using a standard component library in the SIMIT simulation platform, where SIMIT (Simulation Framework for Industrial Automation and Control Systems) is Siemens' simulation platform. When the virtual control system 40 outputs a control command, the SIMIT simulation platform instantly captures the control command and uses it to drive the internal digital twin model. While executing the control command, the digital twin model generates virtual device status signals and writes them into the virtual control system 40 through the second data interaction link 32.

[0043] The virtual control system 40 transmits the virtual device status signal back to the process control system 20 through the first data transmission link 31. The process control system 20 sends the virtual device status signal to the batch control system 10. The batch control system 10 can execute the next formulation stage according to the virtual device status signal. The workflow of the next formulation stage is the same as that of the current formulation stage, which will not be described in detail here.

[0044] Digital twin models are not limited to being built within the SIMIT simulation platform. They can also utilize specialized modeling software such as MATLAB / Simulink, AMESim, and Aspen Plus / Aspen Dynamics to establish high-fidelity fluid, powder, and reaction kinetic models of the lithium-ion battery cathode production process. These models can be packaged into FMUs (Functional Mock-up Units) according to the FMI (Functional Mock-up Interface) standard and connected to a digital twin platform supporting the FMI standard (such as SIMIT) as the FMU's runtime host. The digital twin platform schedules the FMU to execute model calculations within each simulation time step, achieving data exchange, time synchronization, and joint collaborative simulation with the virtual control system 40, thereby improving the model accuracy, scalability, and simulation realism of the digital twin system.

[0045] Furthermore, the simulation system of the present invention is not limited to deployment on terminal devices, but can also be deployed in the cloud, with each node interacting through a cloud virtual private network.

[0046] In the above embodiments, the batch control system sends the formula parameters to the process control system. The process control system then sends the formula parameters to the virtual control system via a first data transmission link established through a communication bridge. The virtual control system generates control commands based on the formula parameters to drive the digital twin system to execute. Furthermore, the virtual device status signal generated by the digital twin system after executing the control commands is sequentially fed back to the virtual control system via a second data interaction link, then back to the process control system via the first data transmission link, and finally back to the batch control system. This not only establishes a complete data chain from "plan issuance—formula analysis—process control element flow—equipment execution," achieving end-to-end data connectivity verification from production plan issuance to final equipment execution, but also completes closed-loop testing of all elements—"control commands—equipment response—process evolution—feedback adjustment"—without consuming actual materials, thereby reducing verification costs. In addition, the communication bridge enables real-time data interaction between control systems of different architectures in a virtual environment, without relying on any physical hardware.

[0047] In some embodiments, the communication bridge 30 establishes communication connections between the process control system 20 and the virtual control system 40 through a virtual communication interface, and configures the data mapping relationship between the two to construct a first data transmission link 31; the communication bridge 30 also configures an input-output signal mapping relationship between the virtual control system 40 and the digital twin system 50 to construct a second data interaction link 32, thereby realizing bidirectional transmission of recipe parameters, control commands and virtual device status information.

[0048] Specifically, the virtual communication interface can use a virtual network adapter provided by the operating system, such as the Siemens PLCSIM Virtual Ethernet Adapter, and configure virtual communication addresses for the process control system 20 and the virtual control system 40 to be in the same virtual subnet, enabling them to communicate with each other at the network layer. Based on this, the communication bridge 30 can configure address mapping relationships between the transmit data area of ​​the process control system 20 and the receive data area of ​​the virtual control system 40 in the coupling configuration interface of the simulation middleware. For example, the transmit data area and the receive data area can be implemented by data blocks DB501 and DB901 respectively. When the process control system 20 calls the PUT communication command, it can write the recipe parameters into the virtual control system 40 according to this mapping relationship.

[0049] The communication bridge 30 establishes an I / O signal mapping relationship between the virtual control system 40 and the digital twin system 50 in the simulation middleware, such as PCS7_Device_IO_Simulation. This mapping relationship binds the output image area (Q area) address of the virtual control system 40 to the control input pin of the digital twin system 50, and binds the physical quantity output pin of the digital twin system 50 to the input image area (I area) address of the virtual control system 40. During each simulation scan cycle, the output image area state of the virtual control system 40 is automatically written to the corresponding input pin of the digital twin system 50 to drive the model operation. Simultaneously, the virtual device status signals (such as weighing values, temperature, and position signals) calculated by the digital twin system 50 are automatically written to the corresponding address of the input image area of ​​the virtual control system 40. This I / O signal mapping is a periodic hardware register-level mapping, independent of the packetization and depacketization of the communication protocol stack, with a fixed delay of one simulation scan cycle.

[0050] In the above embodiments, the communication bridge 30 achieves real-time data interaction between control systems with different architectures without requiring any physical hardware through a two-layer coupling communication mechanism.

[0051] Optionally, the communication bridge 30 can also be constructed in other ways. For example, in the virtual network environment where the process control system 20 and the virtual control system 40 reside, each can enable the OPC UA Server / Client function or configure the Modbus TCP / IP protocol. The two can perform real-time variable reading / writing and handshaking interaction through the internal virtual loopback network card of the host computer, or an industrial IoT MQTT middleware can be introduced. The process control system 20 and the virtual control system 40 can act as publisher and subscriber, respectively, encapsulating control commands and field feedback into JSON data packets for interaction under a shared topic.

[0052] In some embodiments, such as Figure 2 As shown, the process control system 20 includes a process control platform 21 and a virtual controller 22. The process control platform 21 is used to respond to the current recipe stage sent by the batch control system 10, and after the corresponding equipment stage is activated, it sends the recipe parameters corresponding to the current recipe stage to the virtual controller 22. The virtual controller 22 is used to write the recipe parameters into the first transmit data area, and according to the data mapping relationship established by the communication bridge 30, transmit the recipe parameters in the first transmit data area to the first receive data area corresponding to the virtual control system 40.

[0053] The process control platform 21 is pre-configured with multiple Equipment Phases (EPHs), each corresponding one-to-one with a Recipe Phase (RPH) in the batch control system 10. When the batch control system 10 issues an execution command to the process control system 20 according to the current recipe phase, the corresponding equipment phase in the process control platform 21 is activated. After the equipment phase is activated, the process control platform 21 sends the recipe parameters corresponding to that recipe phase to the virtual controller 22. Upon receiving the recipe parameters, the virtual controller 22 writes the recipe parameters into the first transmit data area and, based on the virtual communication address and data mapping relationship, transmits the recipe parameters in the first transmit data area to the first receive data area corresponding to the virtual control system 40. In one specific implementation, the first transmit data area and the first receive data area are implemented using data blocks, and data writing is completed through the PUT communication command.

[0054] Taking precursor batching as an example, after the batch control system 10 activates the corresponding equipment stage EPH-010 in the process control platform 21, the process control platform 21 sends the formula parameters, including 28 formula parameters such as the precursor target weight of 800.0 kg, the fast / slow feed switching threshold of 95%, and the feed rate of 500 kg / h, to the virtual controller 22. The virtual controller 22 stores these parameters in the first sending data block (e.g., DB501) and writes the parameters in DB501 into the first receiving data block (e.g., DB901) of the virtual control system 40 through the first data transmission link 31. After reading the parameters from the first receiving data block, the virtual control system 40 generates specific equipment control commands (e.g., "open the fast feed valve" and "start the screw feeder to 50 Hz") and outputs them to the digital twin system 50 to drive the model for execution.

[0055] In some embodiments, the virtual control system 40 receives virtual device status information fed back by the digital twin system 50, writes the virtual device status information into the second transmission data area, and transmits the virtual device status information to the second reception data area corresponding to the process control system 20 according to the data mapping relationship of the first data transmission link 31, so as to complete the feedback of virtual device status information.

[0056] Understandably, the feedback of virtual equipment status information and the distribution of formula parameters are both completed through the first data transmission link 31. After receiving the virtual equipment status information fed back by the digital twin system 50 through the second data interaction link 32, the virtual control system 40 determines whether the current process action is completed based on this information. The virtual equipment status information may include equipment action completion signals, equipment operating status signals, and process measurement values; among which, equipment action completion signals may include material arrival or evacuation completion signals, equipment operating status signals may include motor operating status or valve arrival status, and process measurement values ​​may include real-time weight, current temperature, motor speed, or operating current. The virtual control system 40 writes the information that needs to be fed back into the second sending data area and transmits it to the corresponding second receiving data area of ​​the virtual controller 22 according to the data mapping relationship.

[0057] In some embodiments, the digital twin system 50 performs physical evolution calculations of the corresponding process according to control instructions, generates corresponding virtual device status information based on the physical evolution calculations, and writes the virtual device status information into the corresponding input data area of ​​the virtual control system 40 according to the input-output signal mapping relationship established by the second data interaction link 32, so that the virtual control system 40 can make process status judgments.

[0058] Specifically, after receiving a control command, the digital twin system 50 can calculate the physical state evolution of materials and equipment based on the duration, setpoint, or dynamic opening degree of the control command, and generate corresponding virtual equipment status information based on the calculation results. The digital twin system 50 writes the virtual equipment status information into the input data area of ​​the virtual control system 40 according to the input-output signal mapping relationship; in one specific implementation, the input data area is the input image area (I area). The virtual control system 40 reads the virtual equipment status information in the input data area to determine whether the current process action has been completed.

[0059] by Figure 3Taking the communication process shown as an example, the virtual controller 22 includes a first transmitting data area and a second receiving data area, and the virtual control system 40 includes a first receiving data area, a second transmitting data area, an output data area, and an input data area. Each data area can be implemented by DB501, DB500, DB901, DB900, an output image area (Q area), and an input image area (I area), respectively. The virtual controller 22 writes the recipe parameters sent by the process control platform 21 into the first transmitting data area and transmits them to the first receiving data area according to the data mapping relationship of the first data transmission link 31. The virtual control system 40 parses the recipe parameters, generates control commands and writes them into the output data area, and then sends them to the digital twin system 50 according to the input-output signal mapping relationship of the second data interaction link 32. The digital twin system 50 executes the control commands and writes the calculated virtual device status information into the input data area in each simulation cycle. The virtual control system 40 judges the process status based on the virtual device status information, writes the information that needs to be fed back into the second transmitting data area, and then transmits it to the second receiving data area according to the data mapping relationship of the first data transmission link 31.

[0060] It should be noted that the SIMIT platform in this architecture simultaneously carries two types of coupling channels, which together constitute a two-layer IO mapping mechanism. The first type is the Virtual Controller Coupling channel. SIMIT establishes process image coupling with the Virtual Controller 22 (built on PCS7 in this embodiment) through this channel, incorporating the IO variables (including input image areas and output image areas) at the Device Stage (EPH) and Device Module (EM) levels on the Virtual Controller 22 side into the scheduling cycle of the SIMIT simulation bus. The second type is the PLCSIM Advanced Coupling channel, which is the second data interaction link 32 of this invention. Both types of coupling channels are uniformly scheduled within the SIMIT platform, jointly realizing the end-to-end IO data flow from the Virtual Controller 22 side to the Virtual Control System 40 side.

[0061] The first type is the Virtual Controller Coupling channel, which can serve as one implementation of the first data transmission link 31. SIMIT establishes process image coupling with the Virtual Controller 22 through this channel, and uses the mapping relationship between data areas as the basis for data interaction. In one specific implementation, the data area consists of data blocks (DBs). The entire data block is written between the first sending data area (e.g., DB501) of the Virtual Controller 22 and the first receiving data area (e.g., DB901) of the Virtual Control System 40 via the PUT communication command to transmit recipe parameters. In reverse transmission, virtual device status information can be transmitted between the second sending data area and the second receiving data area.

[0062] The second type is the PLCSIM Advanced Coupling channel, which is the second data interaction link 32 of this invention. This coupling channel allows SIMIT to communicate with a virtual PLC (e.g., the S7-1500 series) via the PLCSIM Advanced software interface. Using I / O signal mapping as the data interaction carrier, within each simulation scan cycle, the output image area (Q area) status of the virtual control system 40 is automatically written to the corresponding input pin of the digital twin system 50. Simultaneously, the virtual device status signals (such as weighing values, temperature, and position signals) generated by the digital twin system 50 are automatically written to the input image area (I area) of the virtual control system 40. This I / O signal mapping is a periodic hardware register-level mapping, independent of the packetization and depacketization of the communication protocol stack, with a fixed delay of one simulation scan cycle. It is suitable for data interaction scenarios involving device-level control commands and sensor-level feedback signals with high real-time and accuracy requirements.

[0063] The two types of coupling channels are uniformly scheduled within the SIMIT platform. Specifically, at the coupling configuration level, both the virtual controller 22 coupling channel and the PLCSIM Advanced coupling channel are created and configured in SIMIT's Coupling Editor, with SIMIT managing their activation, deactivation, and lifecycle. At the time scheduling level, each type of coupling is allocated to one of multiple available time slices. The absolute period of the time slice can be configured in the project properties (as short as 1ms). The allocation of the two types of coupling follows these rules: all couplings occupy a maximum of 7 different time slices in total, with smaller time slice numbers indicating higher priority. SIMIT schedules the data interaction of each type of coupling in each simulation cycle according to the priority of the time slices. At the conflict handling level, when the data block mapping of the virtual controller 22 coupling channel and the IO signal mapping of the PLCSIM Advanced coupling channel both point to the same input pin of the same digital twin model in the same simulation cycle, SIMIT prioritizes the IO signal mapping of the PLCSIM Advanced coupling channel and uses the data of the virtual controller 22 coupling channel as a redundancy check reference, thereby ensuring the determinism of control instructions at the hardware register level.

[0064] Through the aforementioned two-layer mapping mechanism, the recipe parameters of the batch control logic and the virtual device status information are transmitted bidirectionally between the virtual controller 22 and the virtual control system 40 via the first data transmission link 31. Device-level control commands and sensor-level feedback information interact between the virtual control system 40 and the digital twin system 50 via the second data interaction link 32. These two types of links work together to form a closed-loop data channel from the batch control system 10 to the digital twin system 50, and then back from the digital twin system 50 to the batch control system 10.

[0065] In some embodiments, the virtual controller 22 sends a communication status detection signal to the virtual control system 40 according to a preset period; if no response signal is received from the virtual control system 40 within the preset period, it determines that the communication between the process control system 20 and the virtual control system 40 is abnormal, controls the current equipment stage to maintain the current execution state, sends a communication abnormality alarm message to the batch control system 10, and controls the digital twin system 50 to suspend the simulation execution of the current process; after communication is restored, the simulation verification of the corresponding process continues to be executed.

[0066] Specifically, the communication status detection signal can be implemented using a heartbeat signal. For example, the virtual controller 22 toggles the heartbeat bit in the data transmission area every 500ms. Upon receiving this heartbeat signal, the virtual control system 40 toggles the corresponding response bit and sends it back. If the virtual controller 22 does not receive a response signal within a preset period, it determines that the communication is abnormal. In the event of a communication abnormality, the virtual controller 22 controls the current device stage to maintain its current execution state, sends a communication abnormality alarm message to the batch control system 10, and causes the digital twin system 50 to suspend the physical evolution calculation of the current process. After communication is restored, the hold and pause states are lifted, and the simulation verification of the corresponding process continues from the paused position. The above time parameters and signal forms are only examples and can be set according to the simulation cycle and communication load.

[0067] Through the above-mentioned communication status detection and anomaly handling mechanism, the equipment stage can be maintained, the simulation execution can be suspended, and the recipe stage can be prevented from continuing to flow when communication is abnormal, so as to avoid mismatch between control state and simulation state; after communication is restored, the corresponding process can continue to be executed, which is conducive to maintaining the continuity and traceability of verification data.

[0068] In some embodiments, the batch control system 10 generates a control formula based on the material production formula, determines the current formula stage based on the control formula, activates the corresponding equipment stage in the process control system 20 based on the current formula stage, and sends the formula parameters corresponding to the current formula stage to the process control system 20.

[0069] Specifically, the batch control system 10 first acquires the material production formula, which includes standardized information such as the sequence of process steps, the types of equipment required for each step, and process parameters. Based on the ISA-88 batch control standard, the batch control system 10 breaks down the main formula into multiple sequentially arranged formula stages, such as "precursor batching operation," "lithium salt batching operation," "mixing operation," and "discharging operation." Simultaneously, it establishes multiple corresponding equipment stages in the process control platform 21 and initially encapsulates equipment modules (EMs) at this level, such as batching sequence control (SFC) and mixing segment control (SFC). The batch control system 10 executes a resource allocation algorithm based on the availability status of each equipment entity in the current virtual production line to obtain the control formula. After the control formula is generated, the batch control system 10 arranges the formula stages according to their order to determine the current formula stage to be executed. At batch startup, the current formula stage is the first formula stage in the control formula; during subsequent operation, the current formula stage progresses based on the completion status of the previous formula stage.

[0070] In the batch control system 10, each formulation stage is linked to each device stage in the process control platform 21 via a bidirectional call and status synchronization mapping link. Once the batch control system 10 determines the current formulation stage, it sends an activation command to the process control platform 21 through a standard communication interface, activating the corresponding device stage in the process control platform 21. After the device stage is activated, the batch control system 10 sends the formulation parameters corresponding to the current formulation stage to the process control platform 21.

[0071] Taking the NCM (nickel-cobalt-manganese) ternary precursor blending batch as an example, after the batch control system 10 obtains the main formula of "NCM ternary precursor blending formula", it breaks it down into formula stages such as "precursor batching operation" (RPH-010) and "mixing operation" (RPH-050). The batch control system 10 generates a control formula through a resource allocation algorithm. After the batch starts, the batch control system 10 determines that the current formula stage is RPH-010 (precursor batching operation), activates the corresponding equipment stage EPH-010 in the process control system 20, and sends formula parameters such as "target weight 800.0 kg, fast addition / slow addition switching threshold 95%" to the process control system 20. The process control system 20 executes specific equipment control logic based on these parameters and provides real-time feedback on the execution status. When the execution status of EPH-010 flips to "Completed", this status is transmitted back to the batch control system 10 via the bidirectional synchronous mapping link between RPH and EPH. The batch control system 10 then advances the formulation step sequence to the next formulation stage (RPH-020, lithium salt batching operation), and so on until all formulation stages are completed.

[0072] Through the above mechanism, the batch control system realizes full-chain automated management from master recipe analysis, equipment resource allocation, control recipe instantiation to the sequential advancement of the recipe stage, ensuring that the batch control process strictly follows the process design requirements.

[0073] In some embodiments, the batch control system 10 filters equipment entities that match the equipment type in the material production formula, then filters candidate equipment entities that are in an idle or ready state according to the operating status of the equipment entities, and determines the target equipment entity based on the rated capacity of the candidate equipment entities and the material requirements corresponding to the material production formula; then, the target equipment entity is assigned to the current control formula and the corresponding equipment identification information is generated.

[0074] The batch control system 10 scans and matches the equipment entities of the current virtual production line according to the following priority order to obtain the control recipe: 1. Equipment type matching: Based on the equipment type in the material production formula (such as NCM mixing machine or weighing and batching system), filter out all entities in the current virtual production line that match the equipment type to obtain the first initial equipment entity; 2. Equipment Status Filtering: From the first initial equipment entity, further filter out equipment entities whose current status is idle or ready, and exclude equipment entities in running, fault, or maintenance status to obtain the second initial equipment entity; 3. Capacity constraint verification: Compare the rated capacity of the second initial equipment entity (such as the nominal volume of the reactor or the maximum load capacity of the weighing hopper) with the total amount of target material in the main formula of this batch to ensure that the rated capacity of the target equipment entity is ≥ the total planned feed amount of this batch × safety margin coefficient (default 1.1). 4. Allocation Confirmation and Locking: Equipment entities (i.e. target entities) that meet all the above conditions are marked as allocated by the system, and their specific equipment entity identifiers are written into the control recipe.

[0075] It should be noted that if no equipment entity is selected, the batch control system 10 places the batch in the waiting queue and returns a "resources insufficient" status code to the manufacturing execution system, suspending work order issuance until equipment resources are released.

[0076] In the above embodiments, equipment in operation, fault, or maintenance status is filtered out by equipment status filtering, and capacity constraint verification is used to ensure that the rated capacity of the selected equipment meets the product requirement of the total amount of target material and the safety margin, thereby ensuring that the allocated equipment entities meet the execution requirements of the current batch in terms of process capability and operating status; and by marking the target equipment as "allocated" and recording its equipment entity identifier, the system can effectively prevent the same equipment from being repeatedly allocated by multiple parallel batches.

[0077] In some embodiments, the digital twin system 50 includes multiple digital twin models. Each digital twin model is established based on historical operating data and performs process simulation calculations according to model parameters; the digital twin model is driven by historical control commands and determined based on the consistency between the model calculation results and the corresponding historical process data.

[0078] Specifically, operational data from multiple historical batches can be extracted from the historical operational database of a real production line. This historical operational data can include historical control commands, process setpoints, and corresponding historical process data for each process stage. Feeding parameters, motor dynamic response parameters, thermal balance parameters, and material evolution parameters are determined based on this historical operational data, and a model to be verified is established based on these model parameters. Subsequently, the historical control commands are used to drive the model to be verified, obtaining the model calculation results. These results are then compared with the historical process data corresponding to the same historical control commands to determine their consistency.

[0079] In some embodiments, the digital twin model is validated by the consistency between the model calculation results and historical process data. When the consistency meets the preset requirements, the corresponding model is used as the digital twin model; when the consistency does not meet the preset requirements, the model parameters are optimized, and the digital twin model is reconstructed based on the optimized model parameters.

[0080] Specifically, the consistency of each key variable can be determined using normalized root mean square error or other accuracy evaluation indicators. When the consistency of all key variables meets the preset requirements, the model validation is successful; when the consistency of at least one key variable fails to meet the preset requirements, parameter identification or optimization is performed again based on historical operating data, and the optimized model parameters are used to perform process simulation calculations and consistency verification again until the preset requirements are met.

[0081] In the above embodiments, by performing offline identification and online accuracy verification on the model parameters, a digital twin model that can reflect the real production process is obtained, thereby further improving the accuracy of simulation verification.

[0082] For example, multiple digital twin models may include a weighing and batching model, a motor dynamic response model, a cavity temperature projection model, and a material evolution model.

[0083] The weighing and batching model is a series model built on the structure of "feeding bin → feeding valve → screw feeder → weighing hopper". It has an embedded dynamic weight accumulation algorithm (W(t)=W(t-1)+F×Δt). When the control command is to open the fast-addition valve, the weight change is calculated in real time, and the position judgment feedback is output when the threshold is reached.

[0084] The motor dynamic response model can use a first-order inertial transfer function to characterize the variable frequency speed regulation dynamic response of actuators such as fly knife motors, and calculate the motor operating current and torque feedback based on load characteristics.

[0085] The cavity temperature estimation model is based on a simplified heat balance equation (dT / dt=(Q_friction-Q_dissipation) / (m×C_p)). Based on the dynamic frictional heat generation caused by the flight speed command, the cavity temperature change is calculated in real time and analog feedback is generated.

[0086] Material evolution models are used to characterize the dynamic changes in batch-level material concentration, uniformity, or particle size. Taking the mixing process as an example, based on the material mass conservation equation and the hybrid dynamics equation, during the switching process of each step in the equipment module-level mixing sequence control, the concentration uniformity index and particle size distribution trend of each component in the cavity can be calculated, and a process compliance signal can be generated for the process control system 20 to determine whether the current equipment stage has been completed. This model can be used in conjunction with the weighing and batching model to characterize the material state evolution process from the formation of the batching ratio to the achievement of preset mixing uniformity requirements.

[0087] In an alternative implementation, faults can also be injected into the digital twin model or recipe to verify multi-level interlocking capabilities. Specifically, the load torque of the flying knife can be forcibly increased to 130%, and the virtual control system 40 will immediately stop output after recognizing the overload to protect the equipment, thereby achieving equipment-level interlocking capability verification. Alternatively, the high-temperature limit can be set to a negative number, and the batch control system 10 will identify illegal parameters through logical cross-validation during the work order parsing stage and refuse to issue the work order, thus moving the error prevention checkpoint forward and achieving protection verification at the recipe stage / equipment stage.

[0088] In summary, according to the material batch control full-process simulation system of this embodiment, the formula parameters are sent from the batch control system 10 to the virtual control system 40 via the process control system 20 and the first data transmission link 31. The virtual control system 40 generates control commands and drives the digital twin system 50 to execute them through the second data interaction link 32. The virtual equipment status information generated by the digital twin system 50 is then fed back to the virtual control system 40, the process control system 20, and the batch control system 10 in sequence. This forms a closed loop in which the formula stage, equipment stage, control commands, process simulation, and status feedback are interconnected, which can be used to verify the data transmission, stage transition, and control logic of the entire batch control process.

[0089] Corresponding to the above system embodiments, this invention also proposes a full-process simulation method for material batch control. For example... Figure 4 As shown, the method may include steps S101 to S110.

[0090] S101, the batch control system acquires the material production formula and generates a control formula based on the material production formula.

[0091] S102, the batch control system determines the current formula stage based on the control formula and generates the corresponding formula parameters.

[0092] S103, the process control system activates the corresponding equipment stage according to the current formula stage and receives the formula parameters.

[0093] S104, the communication bridge transmits the recipe parameters to the virtual control system through the first data transmission link.

[0094] S105, the virtual control system generates control commands based on the formula parameters and sends the control commands to the digital twin system.

[0095] S106, the digital twin system performs process simulation according to control commands and generates corresponding virtual equipment status information.

[0096] S107, the communication bridge feeds back the virtual device status information to the virtual control system through the second data interaction link.

[0097] S108, the virtual control system feeds back the virtual device status information to the process control system through the first data transmission link.

[0098] S109, the process control system sends the virtual device status information to the batch control system.

[0099] S110, the batch control system determines whether the current formulation stage is completed based on the virtual device status information, and enters the next formulation stage when the current formulation stage is completed, repeating the corresponding steps until all formulation stages in the control formulation are completed, so as to realize the data connection verification of the entire process of material batch control.

[0100] In some embodiments, the communication bridge establishes communication connections between the process control system and the virtual control system through a virtual communication interface, and configures the data mapping relationship between the two to construct a first data transmission link; the communication bridge also configures the input and output signal mapping relationship between the virtual control system and the digital twin system to construct a second data interaction link.

[0101] In some embodiments, the process control system includes a process control platform and a virtual controller. The process control platform responds to the current recipe stage sent by the batch control system, and after the corresponding equipment stage is activated, sends the recipe parameters corresponding to the current recipe stage to the virtual controller. The virtual controller writes the recipe parameters into a first transmit data area, and transmits the recipe parameters in the first transmit data area to the first receive data area corresponding to the virtual control system according to the data mapping relationship established by the communication bridge.

[0102] In some embodiments, the virtual control system receives virtual device status information fed back by the digital twin system, writes the virtual device status information into the second transmission data area, and transmits the virtual device status information to the second reception data area corresponding to the process control system according to the data mapping relationship of the first data transmission link, so as to complete the feedback of virtual device status information.

[0103] In some embodiments, the virtual controller sends a communication status detection signal to the virtual control system according to a preset period; if no response signal is received from the virtual control system within the preset period, it determines that the communication between the process control system and the virtual control system is abnormal, controls the current equipment stage to maintain the current execution state, sends a communication abnormality alarm message to the batch control system, and controls the digital twin system to suspend the simulation execution of the current process; after communication is restored, the simulation verification of the corresponding process continues to be executed.

[0104] In some embodiments, the digital twin system performs physical evolution calculations of the corresponding process according to control instructions, generates corresponding virtual device status information based on the physical evolution calculations, and writes the virtual device status information into the input data area of ​​the virtual control system according to the input-output signal mapping relationship established by the second data interaction link, so that the virtual control system can make process status judgments.

[0105] In some embodiments, the batch control system generates a control formula based on the material production formula, determines the current formula stage based on the control formula, activates the corresponding equipment stage in the process control system based on the current formula stage, and sends the formula parameters corresponding to the current formula stage to the process control system.

[0106] In some embodiments, the batch control system filters matching equipment entities based on the equipment type in the material production formula, filters candidate equipment entities that are in an idle or ready state based on the operating status of the equipment entities, determines the target equipment entity based on the rated capacity of the candidate equipment entities and the material requirements corresponding to the material production formula, assigns the target equipment entity to the current control formula, and generates corresponding equipment identification information.

[0107] In some embodiments, a digital twin system includes multiple digital twin models. Each digital twin model is built based on historical operating data and performs process simulation calculations according to model parameters; the digital twin model is driven by historical control commands and its operation is determined based on the consistency between the model calculation results and the corresponding historical process data.

[0108] In some embodiments, the digital twin model is verified by the consistency between the model calculation results and historical process data; when the consistency meets the preset requirements, the corresponding model is used as the digital twin model; when the consistency does not meet the preset requirements, the model parameters are optimized, and the digital twin model is reconstructed based on the optimized model parameters.

[0109] In some embodiments, the multiple digital twin models include a weighing and batching model, a motor dynamic response model, a cavity temperature extrapolation model, and a material evolution model.

[0110] In some embodiments, the model parameters include feeding parameters, motor dynamic response parameters, thermal balance parameters, and material evolution parameters.

[0111] The material batch control full-process simulation method according to embodiments of the present invention forms a complete closed loop from material production formula to execution by digital twin system and back to batch control system by issuing formula parameters step by step, driving simulation with control commands, feeding back virtual equipment status step by step, and advancing the formula stage in a cyclical manner. This enables the verification of data transmission, control logic and stage flow of the entire material batch control process.

[0112] It should be noted that the specific implementation method of the material batch control full-process simulation method in this embodiment of the invention corresponds one-to-one with the specific implementation method of the material batch control full-process simulation system in the aforementioned embodiment of the invention, and will not be repeated here.

[0113] Corresponding to the above embodiments, this invention also proposes a computer-readable storage medium storing a computer program. When executed by a processor, this computer program implements the aforementioned material batch control full-process simulation method. By executing this computer program, a closed-loop verification process can be formed, encompassing formula parameter distribution, process simulation, virtual equipment status feedback, and formula stage advancement.

[0114] Corresponding to the above embodiments, this invention also proposes a communication bridge for full-process simulation verification of material batch control. The communication bridge includes a communication connection module, a data mapping module, and a signal mapping module. The communication connection module establishes a data transmission link between the process control system and the virtual control system through a virtual communication interface; the data mapping module configures the data mapping relationship between the process control system and the virtual control system to transmit formula parameters and virtual equipment status information between corresponding data areas; the signal mapping module establishes the input / output signal mapping relationship between the virtual control system and the digital twin system to achieve the interaction of control commands and virtual equipment status information. Each module can be implemented by a software function module in the communication bridge, or it can be implemented collaboratively by interfaces, processors, and memory with corresponding functions.

[0115] It should be noted that the logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be specifically implemented in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include: an electrical connection having one or more wires (electronic device), a portable computer disk drive (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Alternatively, the computer-readable medium may be paper or other suitable media on which the program can be printed, since the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0116] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0117] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0118] Furthermore, the terms "first," "second," etc., used in the embodiments of this invention are for descriptive purposes only and should not be construed as indicating or implying relative importance, or implicitly specifying the number of technical features indicated in this embodiment. Therefore, features defined with terms such as "first" and "second" in the embodiments of this invention can explicitly or implicitly indicate that the embodiment includes at least one of those features. In the description of this invention, the word "multiple" means at least two or more, such as two, three, four, etc., unless otherwise explicitly specified in the embodiments.

[0119] In this invention, unless otherwise explicitly specified or limited in the embodiments, the terms "installation," "connection," "joining," and "fixing" appearing in the embodiments should be interpreted broadly. For example, a connection can be a fixed connection, a detachable connection, or an integral part; it can also be a mechanical connection, an electrical connection, etc. Of course, it can also be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components, or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific implementation.

[0120] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A material batch control full-process simulation system, characterized in that, include: Batch control systems, process control systems, communication bridges, virtual control systems, and digital twin systems; The batch control system is connected to the process control system. The batch control system is used to acquire the material production formula, determine the current formula stage based on the material production formula, and send the formula parameters corresponding to the current formula stage to the process control system. The process control system is pre-set with multiple equipment stages, and each equipment stage corresponds one-to-one with the formulation stage. The communication bridge is used to establish a first data transmission link between the process control system and the virtual control system, and to establish a second data interaction link between the virtual control system and the digital twin system. The process control system is also used to map the recipe parameters to the virtual control system through the first data transmission link. The virtual control system is connected to the digital twin system. The virtual control system is used to generate control commands based on the formula parameters and send the control commands to the digital twin system so that the digital twin system executes the control commands. It also receives virtual device status signals fed back by the digital twin system through the second data interaction link and maps the virtual device status signals to the process control system through the first data transmission link. The digital twin system is built based on the material production process. The process control system is also used to send the virtual device status signals to the batch control system so that the batch control system completes full-process data connectivity verification based on the virtual device status signals.

2. The material batch control full-process simulation system according to claim 1, characterized in that, The communication bridge is also used for: A communication connection is established between the process control system and the virtual control system via a virtual communication interface, and a data mapping relationship is configured between the process control system and the virtual control system to construct the first data transmission link; and, An input-output signal mapping relationship is configured between the virtual control system and the digital twin system to construct the second data interaction link, wherein the second data interaction link is used to realize the bidirectional transmission of the recipe parameters, the control commands and the virtual device status information.

3. The material batch control full-process simulation system according to claim 2, characterized in that, The process control system includes a process control platform and a virtual controller; The process control platform is used to respond to the current recipe stage sent by the batch control system, and after the corresponding equipment stage is activated, it sends the recipe parameters corresponding to the current recipe stage to the virtual controller. The virtual controller is used to write the recipe parameters into the first transmit data area, and transmit the recipe parameters in the first transmit data area to the first receive data area corresponding to the virtual control system according to the data mapping relationship established by the communication bridge.

4. The material batch control full-process simulation system according to claim 3, characterized in that, The virtual control system is also used for: Receive virtual device status information fed back by the digital twin system; Write the virtual device status information into the second data transmission area; Based on the data mapping relationship established by the first data transmission link, the virtual device status information is transmitted to the second receiving data area corresponding to the process control system to complete the feedback of the virtual device status information.

5. The material batch control full-process simulation system according to claim 3, characterized in that, The virtual controller is also used for: Send communication status detection signals to the virtual control system according to a preset cycle; If no response signal is received from the virtual control system within a preset period, it is determined that the communication between the process control system and the virtual control system is abnormal. The system controls the current equipment to maintain its current execution state, sends a communication abnormality alarm to the batch control system, and controls the digital twin system to pause the simulation execution of the current process. After communication is restored, the simulation verification of the corresponding process continues.

6. The material batch control full-process simulation system according to claim 2, characterized in that, The digital twin system is used for: The physical evolution calculations for the corresponding process are executed according to the control instructions; The corresponding virtual device state information is generated based on the physical evolution calculation; Based on the input-output signal mapping relationship established by the second data interaction link, the virtual device status information is written into the corresponding input data area of ​​the virtual control system for the virtual control system to perform process status judgment.

7. The material batch control full-process simulation system according to claim 1, characterized in that, The batch control system is also used for: A control formula is generated based on the material production formula; The current formulation stage is determined based on the control formulation; Activate the corresponding equipment stage in the process control system according to the current formulation stage, and send the formulation parameters corresponding to the current formulation stage to the process control system.

8. The material batch control full-process simulation system according to claim 7, characterized in that, The batch control system is also used for: Based on the equipment type in the material production formula, select equipment entities that match the equipment type; Candidate device entities that are in an idle or ready state are filtered according to the operating status of the device entity. The target equipment entity is determined based on the rated capacity of the candidate equipment entity and the material requirements corresponding to the material production formula; The target device entity is assigned to the current control recipe, and corresponding device identification information is generated.

9. The material batch control full-process simulation system according to claim 1, characterized in that, The digital twin system includes multiple digital twin models, which are constructed in the following ways: Each of the digital twin models is established based on historical operating data, and the process simulation calculations are completed based on the model parameters; The digital twin model is driven by historical control commands and is determined based on the consistency between the model calculation results and the corresponding historical process data.

10. The material batch control full-process simulation system according to claim 9, characterized in that, The digital twin model is verified by the consistency between the model calculation results and historical process data; When the consistency meets the preset requirements, the corresponding model will be used as the digital twin model; When the consistency does not meet the preset requirements, the model parameters are optimized, and the digital twin model is reconstructed based on the optimized model parameters.

11. The material batch control full-process simulation system according to claim 9, characterized in that, The multiple digital twin models include: a weighing and batching model, a motor dynamic response model, a cavity temperature extrapolation model, and a material evolution model.

12. The material batch control full-process simulation system according to claim 9, characterized in that, The model parameters include: feeding parameters, motor dynamic response parameters, thermal balance parameters, and material evolution parameters.

13. A communication bridge for simulation verification of the entire process of batch control of materials, characterized in that, include: The communication connection module is used to establish a data transmission link between the process control system and the virtual control system; The data mapping module is used to configure the data mapping relationship between the process control system and the virtual control system, so as to realize the data transmission of formula parameters and virtual equipment status information; The signal mapping module is used to establish the input-output signal mapping relationship between the virtual control system and the digital twin system, so as to realize the interaction of control commands and virtual device status information.

14. A full-process simulation method for batch control of materials, characterized in that, include: The batch control system acquires the material production formula and generates a control formula based on the material production formula; The batch control system determines the current formula stage based on the control formula and generates the corresponding formula parameters; The process control system activates the corresponding equipment stage according to the current formula stage and receives the formula parameters; The communication bridge transmits the formula parameters to the virtual control system via the first data transmission link; The virtual control system generates control commands based on the recipe parameters and sends the control commands to the digital twin system; The digital twin system performs process simulation according to the control commands and generates corresponding virtual equipment status information; The communication bridge feeds back the virtual device status information to the virtual control system through the second data interaction link; The virtual control system feeds back the virtual device status information to the process control system through a first data transmission link; The process control system sends the virtual device status information to the batch control system; The batch control system determines whether the current formulation stage is completed based on the virtual device status information and proceeds to the next formulation stage, thereby achieving data connectivity verification throughout the entire material batch control process.

15. A computer-readable storage medium, characterized in that, It stores a computer program, which, when processed by a processor, executes the material batch control full-process simulation method as described in claim 14.

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