Process model building system and process model building method

Abstract

To support construction of a process model for predicting a physical quantity in a process.SOLUTION: A process model construction system for constructing a process model for predicting a physical quantity in a process includes a storage unit configured to store a unit model which is a mathematical model corresponding to each of a plurality of phenomena related to a process and information of a plurality of element blocks corresponding to a plurality of components constituting the process, and an arithmetic unit configured to output a process model for predicting the physical quantity in the target process based on information of the unit model related to the plurality of element blocks related to the target process and coupling information indicating a relationship between the plurality of element blocks related to the target process.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a process model construction system and a process model construction method. [Background technology]

[0002] Conventionally, there has been a technology for reducing the workload when constructing an initial plant model by constructing a system that extracts necessary models from a plant model / unit library prepared in advance and automatically generates a prototype of the plant model, such as the technology described in Japanese Patent Laid-Open Publication No. 2013-109711. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-109711 Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned conventional technology allows for combinations on a device-by-device basis, but does not assume that when multiple physical phenomena exist within a device, models for each physical phenomenon are stored as data or combined. When building a process model with an eye toward automated plant operation, it is necessary to quickly build a process model that can grasp the general shape of dynamic characteristics. Individual models for reactions, heat transfer, etc. are known, but integrating these models to build a process model requires specialized knowledge, and there are limitations on the number of human resources available. Therefore, there is a need for technology that supports the construction of process models for predicting physical quantities in processes. [Means for solving the problem]

[0005] In order to achieve the above object, one representative process model construction system of the present invention is a process model construction system that constructs a process model for predicting physical quantities in a process, and is characterized by comprising: a memory unit that stores unit models, which are mathematical models corresponding to each of a plurality of process-related phenomena, and information on a plurality of element blocks corresponding to each of a plurality of components that make up the process; and a calculation unit that outputs a process model for predicting physical quantities in a target process, based on information on the unit models related to the plurality of element blocks related to a target process and connection information that indicates the relationships between the plurality of element blocks related to the target process. Furthermore, one representative process model construction method of the present invention is a process model construction method for constructing a process model for predicting physical quantities in a process, characterized by including the steps of: storing, in a storage unit, unit models, which are mathematical models corresponding to each of a plurality of process-related phenomena, and information on a plurality of element blocks corresponding to each of a plurality of constituent elements that make up the process, by a computer; constructing a process model for predicting physical quantities in the target process based on information on the unit models related to the plurality of element blocks related to the target process and connection information indicating the relationships between the plurality of element blocks related to the target process; and outputting the constructed process model. [Effects of the Invention]

[0006] According to the present invention, it is possible to support the construction of a process model for predicting physical quantities in a process. Problems, configurations, and effects other than those described above will become apparent from the following description of the embodiments. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is an explanatory diagram illustrating the construction of a process model according to an embodiment. [Figure 2] Specific examples of screens displayed on user terminals [Figure 3] Process model construction system configuration diagram (part 1) [Figure 4] Process model construction system configuration diagram (part 2) [Figure 5] Flowchart showing the processing steps for model construction [Figure 6] Flowchart showing details of the model building process [Figure 7] Specific data example (part 1) [Figure 8] Specific data example (part 2) [Figure 9] Display variation (part 1) [Figure 10] Display variation (part 2) DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, a representative embodiment for carrying out the present invention will be described with reference to the drawings as appropriate. FIG. 1 is an explanatory diagram of the construction of a process model in an embodiment. The system disclosed in the embodiment stores mathematical model data 55 in a storage unit. The mathematical model data 55 is a mathematical model corresponding to each of a plurality of process-related phenomena. The plurality of process-related phenomena are physical and chemical phenomena that occur in the process. The physical and chemical phenomena that occur in the process include reactions, heat transfer, mass transfer, etc. The model construction unit 43 of the system disclosed in the embodiment constructs a model of the target process by combining unit models of phenomena occurring in the target process, with mathematical models corresponding to the phenomena being used as unit models.

[0009] The user operates the user terminal 20 to input specifications for the target process and the connection state of the components. The process specifications include detailed settings for the equipment, materials, and steps. The process components include components related to hard conditions. The process components can be treated as element blocks. In other words, information about one element is treated as one set, and the relationships between the elements are managed as the connection state of the element blocks. It is preferable that element blocks correspond to spatial elements, which are physical components that occupy a certain range in real space. For example, the material of a process and the jacket of a reactor that contains the material can be represented as element blocks, and the presence of the material in the jacket can be represented by a combination of element blocks. Furthermore, the relationships between the components can be easily manipulated by a graphic user interface that associates icons with element blocks, displays the icon arrangement, and accepts changes to the icon arrangement.

[0010] 1 illustrates a jacket and a liquid phase material as spatial elements. The model construction unit 43 associates icons with the liquid phase and the jacket, and when it receives an operation to drag the liquid phase onto the jacket, it indicates that the liquid phase will enter the jacket and combines the element block of the jacket with the element block of the liquid phase.

[0011] In Fig. 1, a mathematical model of a reaction and a mathematical model of heat transfer are associated with the element block of the liquid phase. Also, a mathematical model of heat transfer is associated with the element block of the jacket. If the liquid phase and the jacket are connected, the model construction unit 43 constructs a process model assuming that heat transfer in the liquid phase and heat transfer in the jacket are the same phenomenon, i.e., heat transfer occurs between the liquid phase and the jacket.

[0012] Fig. 2 is a specific example of a screen displayed by the user terminal 20. In the example of Fig. 2, the user terminal 20 displays a process specification input field, a list of process elements, a model construction execution button, a reactor configuration diagram, and a model formula.

[0013] The process specification input field displays the process specification entered by the user. Specific examples of process specifications will be described later. The process element list displays a list of process components, including a number indicating a row in the list, the name of the spatial element, an icon of the spatial element, the name of the phenomenon, components of the phenomenon, and a check box for the modeling target.

[0014] For example, in row number "1," the spatial element name is "liquid phase," the phenomena are "reaction" and "heat transfer," and the components are "component i" and "component m." Similarly, in row number "2," the spatial element name is "jacket," the phenomenon is "heat transfer," and the component is "none."

[0015] The check box for the modeling target is used by the user to specify whether or not to take the target into consideration when modeling. Checked components are incorporated into the process model. Components that are not checked will not be incorporated into the process model. In the list of process elements, the phenomenon, component, and modeling target checkboxes are items that are input by the user.

[0016] The reactor configuration diagram shows the connections between the components. The user can drag an icon from the list of process elements and drop it into a display area that shows the connections between the components. The system then accepts operations to change the relative positions of multiple icons within the display area, and the relative positions of the icons indicate the relative positions of the element blocks in real space, generating connection information that shows the relationships between the components. In other words, the user can indicate the relative positions of the element blocks in real space by manipulating the icons, and connection information is generated from the relative positions of the element blocks.

[0017] When the user terminal 20 accepts the operation of the model construction execution button, the model construction unit 43 constructs a process model. The constructed process model is displayed as a model formula. In FIG. 2, the model formulas for the concentration of component i, the concentration of component m, the liquidus temperature, and the jacket temperature are displayed. Here, the model formula for the liquidus temperature and the model formula for the jacket temperature contain a term UrcArc(Tr-Tc). By including this term in both model formulas, it is possible to express the heat transfer that occurs between the liquidus and the jacket.

[0018] 3 and 4 are configuration diagrams of a process model construction system. The process model construction system includes a server 30. The server 30 is connected to a plant 10 and a user terminal 20.

[0019] The server 30 includes a model construction system 40 and a plant control system 60. The model construction system 40 includes a user collaboration unit 41, a mathematical model acquisition unit 42, a model construction unit 43, and a storage unit 50.

[0020] The storage unit 50 is, for example, a hard disk drive, and stores process specification data 51, reaction specification data 52, element block connection information data 53, space element icon image data 54, mathematical model data 55, and process model data 56.

[0021] The process specification data 51 is data that indicates the specifications of a process for which a model is to be constructed. The reaction specification data 52 is data that indicates the specifications of various reactions that occur in the process. The element block connection information data 53 is connection information that indicates connections between element blocks. The space element icon image data 54 is image data used as an icon of a space element. The mathematical model data 55 is a mathematical model of a physical phenomenon or a chemical phenomenon, and is a unit model used to construct a process model. The process model data 56 is a process model constructed from process specifications and connection information.

[0022] The functions of the user collaboration unit 41, the mathematical model acquisition unit 42, and the model construction unit 43 are realized by, for example, a calculation unit (CPU: Central Processing Unit) executing a predetermined program.

[0023] The user association unit 41 communicates with the user terminal 20 to send and receive data. The user association unit 41 receives process specification data 51, reaction specification data 52, and element block connection information data 53 from the user terminal 20 and stores them in the storage unit 50. The user association unit 41 also transmits spatial element icon image data 54 related to the process to the user terminal 20. When the target process is determined, the user linking unit 41 outputs the process specification data 51, the reaction specification data 52, and the element block connection information data 53 to the mathematical model acquiring unit .

[0024] When generating a process model, the mathematical model acquisition unit 42 performs processing to acquire mathematical models included in the target process. The mathematical model acquisition unit 42 receives process specification data 51, reaction specification data 52, and element block connection information data 53 from the user linkage unit 41, identifies mathematical model data 55 included in the target process, and acquires it from the storage unit 50. The mathematical model acquisition unit 42 outputs the process specification data 51, reaction specification data 52, element block connection information data 53, and mathematical model data 55 to the model construction unit 43. In other words, the mathematical model acquisition unit 42 identifies information on unit models related to multiple element blocks related to the target process based on information on phenomena related to the input element blocks.

[0025] The model construction unit 43 outputs a process model for predicting physical quantities in a target process. The model construction unit 43 generates a model of the target process using process specification data 51, reaction specification data 52, element block connection information data 53, and mathematical model data 55, and stores the model in the storage unit 50 as process model data 56. Specifically, for each element block, the model construction unit 43 constructs a process model by adding a term of a unit model that indicates a phenomenon that interacts between the connected element blocks to the unit model corresponding to the phenomenon that occurs in that element block.

[0026] The plant control system 60 includes a simulation execution unit 61 , a control input calculation unit 62 , a plant cooperation unit 63 , and operation data 64 . The simulation execution unit 61 executes a simulation using the process model data 56 to predict a change in the state of the plant 10 . The control input calculation unit 62 calculates a control input signal to be given to the plant 10 based on the results of the simulation and the current state of the plant 10 acquired from the plant cooperation unit 63 . The plant cooperation unit 63 transmits and receives data to and from the plant 10. Specifically, the plant cooperation unit 63 provides the state of the plant 10 acquired from the plant 10 to the control input calculation unit 62, and transmits a control input signal calculated by the control input calculation unit 62 to the plant 10. In addition, the control input calculation unit 62 accumulates the control input signal transmitted to the plant 10 and the control history acquired from the plant 10 in operation data 64.

[0027] The user terminal 20 includes a server linking unit 21, an input unit 22, and a display unit 23. The server linking unit 21 communicates with the server 30 and transmits and receives data. The server collaboration unit 21 transmits process specification data 51, reaction specification data 52, and element block connection information data 53 to the server 30. The server collaboration unit 21 also receives from the server 30 space element icon image data 54 related to the process.

[0028] The input unit 22 is a pointing device and a keyboard, etc., and the display unit 23 is a liquid crystal display, etc. The input unit 22 and the display unit 23 work together to accept input operations such as changing the position of an icon.

[0029] The input unit 22 receives input of process specification data 51, reaction specification data 52, and element block connection information data 53. The display unit 23 displays the screen shown in Fig. 2. This screen includes a process specification input section, a process element input section, a component linking section, a model construction execution instruction section, and a result display section. The process specification input section corresponds to the process specification input field in Figure 2. The process element input section corresponds to the process element list in Figure 2. The component connection section corresponds to the reactor configuration diagram in Figure 2. The model construction execution instruction section corresponds to the model construction execution button in Figure 2. The result display section corresponds to the model formula in Figure 2.

[0030] The plant 10 includes a server linking unit 11 , a sensor 12 , a control input command unit 13 , a control mechanism 14 , and plant equipment 15 . The server linkage unit 21 transmits the state of the plant equipment 15 identified by the output of the sensor 12 to the server 30 as the state of the plant 10. The server linkage unit 21 also receives a control input signal from the server 30 and passes it to the control input command unit 13. The server linkage unit 21 also transmits a control history by the control input command unit 13 to the server 30.

[0031] The sensor 12 detects the state of the plant equipment 15. The plant equipment 15 includes any equipment such as a reactor, piping, valves, a transport mechanism, etc. The state of the plant equipment 15 includes any index such as temperature or flow rate.

[0032] The control input command unit 13 performs processing to give to the control mechanism 14 a control input signal received from the server 30 or a control input signal operated by a plant manager. The control mechanism 14 is a valve or the like, and controls the plant equipment 15 based on a control input signal.

[0033] 5 is a flowchart showing the processing steps related to model construction. The model construction system 40 sequentially executes the following steps S101 to S106.

[0034] Step S101 The user linking unit 41 accepts input of the process specifications via the user terminal 20. Then, the process proceeds to step S102. Step S102 The user linking unit 41 accepts input of the physical phenomenon, components, and modeling target items of each spatial element via the user terminal 20. Then, the process proceeds to step S103.

[0035] Step S103 The user linking unit 41 accepts the operation of combining the space element icons via the user terminal 20 and registers the combined information, and then proceeds to step S104. Step S104 The model construction unit 43 accepts the model construction execution operation, and then proceeds to step S105.

[0036] Step S105 The model construction unit 43 executes the model construction process, and then the process proceeds to step S106. The model construction unit 43 displays the constructed process model and ends the processing.

[0037] 6 is a flowchart showing the details of the model construction process. The model construction process includes the following steps S201 to S203. Here, the following variable set will be used and a specific example of the model will be described. t: time C r : Heat capacity of the solution C c : Heat capacity of the refrigerant T r : Solution temperature T c : Refrigerant temperature x i : Initiator concentration x m : Monomer concentration U rc : Overall heat transfer coefficient between reactor and jacket A rc : Contact area between reactor and jacket H: Reaction heat coefficient Δx m : Monomer decrease c c : Specific heat capacity of the refrigerant f c : refrigerant flow rate T ci : Jacket inlet temperature T a : Rectification tower internal temperature

[0038] Step S201 The mathematical model acquisition unit 42 reads the modeling target from the process element list information. Then, the process proceeds to step S202. In Fig. 6, the liquidus temperature and the temperature inside the jacket are the modeling targets. Step S202 The mathematical model acquisition unit 42 reads in the mathematical model that defines the physical phenomenon in each spatial element. Then, the process proceeds to step S203. In FIG. 6, the liquidus temperature and the temperature inside the jacket are as follows: Liquidus temperature dT r / dt=1 / C r (HΔx m ) Liquidus temperature dT c / dt=1 / C r (-2c c f c (T c -T ci ))

[0039] Step S203 The model construction unit 43 adds an interaction term to the model according to the connection state of the spatial element icons, and ends the model construction process. In Fig. 6, the liquidus temperature and the temperature inside the jacket are as follows. Liquidus temperature dT r / dt=1 / C r (HΔx m -U rc A rc (T r -T c )) Liquidus temperature dT c / dt=1 / C r (U rc A rc (T r -T c )-2c c f c(T c -T ci ))

[0040] 7 and 8 are specific examples of data. The process specification data 51 associates items and descriptions with the process specification data ID. The items are a list of items used in the target process. A value can be set for the description as needed. For example, if the item is reactor volume, the volume value is set as the description. Also, if the item is a constant, the value of that constant is set. The description is not required, and may not be set depending on the item.

[0041] The reaction specification data 52 associates items and descriptions with reaction specification IDs. The items are a list of items related to the reaction. Values ​​can be set for the descriptions as needed. For example, "components a, b" can be set as the description for the raw material item. Also, "radical polymerization reaction" can be set as the description for the reaction type item.

[0042] The element block connection information data 53 associates a connection information ID with a connection target (1), a connection target (2), and a mathematical model ID. This indicates that the connection target (1) and the connection target (2) are connected, and the mathematical model indicated by the mathematical model ID is applied.

[0043] The space element icon image data 54 associates image data and process specification data IDs with icon image IDs. The mathematical model data 55 associates a mathematical model ID with a mathematical model function and the contents of the mathematical model. The process model data 56 associates a process model ID with a process model function.

[0044] Next, a modified example of the display will be described. In Figure 9, when you point to the term corresponding to heat transfer in the jacket temperature model equation, the display of the heat transfer terms for both the jacket temperature and the liquid phase temperature changes. Furthermore, the reaction equation diagram shows a schematic representation of heat transfer occurring between the liquid phase and the jacket. In this way, changing the display of the terms indicating interactions and displaying them in a schematic representation in the diagram makes it easier to understand the interactions occurring in the target process.

[0045] In the reaction diagram in Figure 10, when heat exchange is present, the liquid phase icon and the jacket icon are displayed so that they touch, and when heat exchange is not present, a gap is provided between the liquid phase icon and the jacket icon. In this way, by displaying a schematic representation of whether or not the interaction between spatial elements is taken into consideration, it becomes easier to understand the assumptions on which the process model was constructed.

[0046] As described above, the system disclosed in the embodiments is a process model construction system that constructs a process model for predicting physical quantities in a process, and includes a memory unit 50 that stores unit models, which are mathematical models corresponding to each of a plurality of process-related phenomena, and information on a plurality of element blocks corresponding to each of a plurality of components that make up the process, and a calculation unit (a user interaction unit 41, a mathematical model acquisition unit 42, and a model construction unit 43) that outputs a process model for predicting physical quantities in a target process, based on information on the unit models related to the plurality of element blocks related to the target process and connection information that indicates the relationship between the plurality of element blocks related to the target process. This configuration and operation can assist in the construction of a process model for predicting physical quantities in a process, allowing even users without specialized knowledge to construct a process model that takes into account interactions between components.

[0047] As an example, the plurality of components that make up the process are characterized by including at least a component related to a hard condition of the target process. The plurality of phenomena may include physical and / or chemical phenomena occurring in the process, including at least a reaction, heat transfer, and mass transfer. With this configuration and operation, the process model construction system can easily construct a process model that takes into account the hard conditions of the process and the various reactions that occur in the process.

[0048] The process model construction system further includes an input unit that receives input of information relating to the relationships between the plurality of element blocks that are related to the target process. The input unit receives input of information on phenomena related to the element blocks, and the calculation unit identifies information on the unit models related to the plurality of element blocks related to the target process based on the input information on phenomena related to the element blocks. This configuration and operation allows a process model to be easily constructed based on input from a user. The input unit may be provided in, for example, a terminal connected to the calculation unit via a network, allowing the user to input various information remotely.

[0049] The input unit receives information on the layout of icons corresponding to the element blocks, and the calculation unit generates the combination information based on the input information on the layout of the icons. Furthermore, the element blocks correspond to components that occupy a predetermined range in real space, the connection information indicates the positional relationship of the element blocks in real space, and the calculation unit constructs the process model for each of the element blocks by adding a term for a unit model that indicates a phenomenon that interacts between the connected element blocks to a unit model that corresponds to a phenomenon that occurs in the element block. According to this configuration and operation, the user can intuitively specify the relationships between elements, and the calculation unit can easily construct a process model from the relationships between elements.

[0050] The system may further include a control input calculation unit that calculates a control input for the plant based on the process model constructed by the calculation unit and information indicating the state of the plant. According to this configuration, automatic control of the plant can be realized using the process model.

[0051] The present invention is not limited to the above-described embodiment, but includes various modifications. For example, the above-described embodiment has been described in detail to clearly explain the present invention, and is not necessarily limited to an embodiment including all of the described configurations. Furthermore, configurations can be replaced or added, not limited to deletion. In the above embodiment, an example was shown in which a check box for a modeling target is provided for each spatial element, but if a plurality of phenomena are associated with a spatial element, a check box may be provided for each phenomenon. Furthermore, the spatial element may include any element such as a fractionator or a catalyst. [Explanation of symbols]

[0052] 10: Plant, 11: Server linkage unit, 12: Sensor, 13: Control input command unit, 14: Control mechanism, 15: Plant equipment, 20: User terminal, 21: Server linkage unit, 22: Input unit, 23: Display unit, 30: Server, 40: Model construction system, 41: User linkage unit, 42: Mathematical model acquisition unit, 43: Model construction unit, 50: Memory unit, 51: Process specification data, 52: Reaction specification data, 53: Element block connection information data, 54: Spatial element icon image data, 55: Mathematical model data, 56: Process model data, 60: Plant control system, 61: Simulation execution unit, 62: Control input calculation unit, 63: Plant linkage unit, 64: Operation data

Claims

1. A process model construction system for constructing a process model for predicting a physical quantity in a process, comprising: a storage unit that stores unit models, which are mathematical models corresponding to each of a plurality of phenomena related to the process, and information on a plurality of element blocks corresponding to each of a plurality of constituent elements that make up the process; a calculation unit that outputs a process model for predicting a physical quantity in a target process based on information on the unit model related to the plurality of element blocks related to the target process and connection information that indicates a relationship between the plurality of element blocks related to the target process. A process model construction system comprising:

2. 2. The process model construction system according to claim 1, A process model construction system, wherein the plurality of components constituting the process includes at least a component related to a hard condition of the target process.

3. 2. The process model construction system according to claim 1, The process model construction system is characterized in that the plurality of phenomena include physical phenomena and / or chemical phenomena occurring in the process.

4. 4. The process model construction system according to claim 3, The process model construction system is characterized in that the physical and / or chemical phenomena include at least a reaction, a heat transfer, and a mass transfer.

5. 2. The process model construction system according to claim 1, The process model construction system further comprises an input unit that receives input of information regarding the relationships between the plurality of element blocks related to the target process.

6. 6. The process model construction system according to claim 5, the input unit receives information on a phenomenon related to the element block, the calculation unit identifies information on the unit model related to a plurality of the element blocks related to the target process based on information on a phenomenon related to the input element block.

7. 6. The process model construction system according to claim 5, the input unit receives input of information regarding the layout of icons corresponding to the element blocks, The process model building system is characterized in that the calculation unit generates the connection information based on input information about the arrangement of the icons.

8. 2. The process model construction system according to claim 1, the element block corresponds to a component occupying a predetermined range in real space, the connection information indicates a positional relationship of the element blocks in real space; a process model construction system characterized in that the calculation unit constructs the process model by adding, for each of the element blocks, a term of a unit model that indicates a phenomenon that interacts between connected element blocks to a unit model that corresponds to a phenomenon that occurs in the element block.

9. 2. The process model construction system according to claim 1, a control input calculation unit that calculates a control input for the plant based on the process model constructed by the calculation unit and information indicating a state of the plant.

10. A process model construction method for constructing a process model for predicting a physical quantity in a process, comprising: The computer storing, in a storage unit, unit models that are mathematical models corresponding to each of a plurality of phenomena related to the process and information on a plurality of element blocks corresponding to each of a plurality of constituent elements that make up the process; constructing a process model for predicting physical quantities in the target process based on information on the unit model related to the plurality of element blocks related to the target process and connection information indicating relationships between the plurality of element blocks related to the target process; and outputting the constructed process model. A process model construction method comprising:

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