Automation Digital Twins for Runtime Switching and Safe Commissioning
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Solution Overview
Problem
Existing methods for engineering automation systems in process plants require switching between simulation and engineering, leading to inconsistencies and parameterization errors due to decoupled processes, which can endanger the real plant.
Innovation Solution
Implementing virtual components as digital twins parallel to real components during engineering, allowing flexible and phased commissioning of automation programs and plant diagrams, with the ability to switch between real and virtual components at runtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation and engineering are decoupled processes requiring switching between them, then automation programs can be tested before deployment, but inconsistencies and parameterization errors occur leading to reduced reliability
Solution Approach 1:
The patent merges simulation and engineering into a single integrated process by embedding virtual components directly within the engineering environment. This allows automation programs to be developed, tested, and validated without switching between separate simulation and engineering tools, eliminating inconsistencies and parameterization errors while maintaining process simplicity.
Solution Approach 2:
The patent introduces virtual components as intermediaries that bridge simulation and engineering. These virtual components allow engineers to test automation programs in a simulated environment while working within the actual engineering tool, serving as a mediator that connects both worlds without requiring separate processes.
2Ease of operation
If virtual components are integrated into the engineering process, then testing and correction can be performed without switching processes, but the engineering system complexity increases
Solution Approach 1:
The patent segments the engineering system into real components and virtual components that can be independently managed and configured. This segmentation allows virtual components to be added without affecting the core engineering system, enabling easy testing and commissioning while keeping the overall system architecture manageable through modular organization.
3Productivity
If digital twins are used for operational optimization, then real-time testing and correction are enabled, but the system requires additional virtualization infrastructure
Solution Approach 1:
The patent creates virtual components during the engineering phase rather than requiring separate digital twin infrastructure during operation. This preliminary action allows testing and validation to be completed beforehand, enabling operational optimization without requiring additional virtualization infrastructure to be deployed in the operational system.
Data Source
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AI summary
The invention relates to a method for engineering an automation system (A). An automation system (A) is usually tested before being put into operation. For each real component (OS1, OS2, AS1, AS2), a so-called digital twin or a virtual component (VOS1, VO2, VAS1, VAS2) is generated and loaded onto a server (ES, S) in order to perform the function of the real components in a simulated manner in place of said real components. It is thus possible for a user to replace various real components with virtual components during the engineering process and to check or simulate the function of the automation system. This makes it possible to perform a synchronous optimisation of automation systems or to put automation programmes and system displays into operation in a coexistent, safe, flexible, and incremental manner.