Control Device Simulation via Segmented Process Model
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Solution Overview
Problem
Existing control devices require external simulation devices to simulate industrial technical processes, which is cumbersome and limits real-time simulation capabilities, as they need to implement complete or partial models of the process, making it difficult to test control specifications without actual control interventions.
Innovation Solution
A control device that allows simulation without connecting simulation devices, by implementing a model of the industrial technical process only for simulated peripheral units, while non-simulated units operate as usual, using a data exchange memory area to manage input and output data separately or jointly, with a router to manage data flow based on simulation status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complete model of the industrial technical process is implemented in a computer for simulation, then simulation capability is provided, but real-time capability is lost and considerable time expenditure is required for model creation
Solution Approach 1:
The patent segments the simulation approach by implementing only a model of the industrial technical process in the computer while using the actual control device and peripheral units for control operations. This partial simulation model approach reduces model creation time while maintaining simulation capability for testing control specifications.
Solution Approach 2:
The patent introduces communication connections as an intermediary between the computer (with process model), control device, and peripheral units. This allows the system to exchange data and signals, enabling the computer to provide input data to the control process while the control device processes control instructions iteratively.
2Speed
If peripheral units are connected to communication connections for actual control operations, then real-time control capability is achieved, but simulation capability is reduced
Solution Approach 1:
The patent makes the system dynamic by allowing peripheral units to be selectively connected or disconnected from communication connections. During normal operation, peripheral units are connected for real-time control. During simulation, they can be disconnected and replaced by the computer model, enabling flexible switching between operational modes.
Solution Approach 2:
The control device is designed with universal functionality to operate in multiple modes: normal control operation with actual peripheral units and simulation mode with computer-generated input data. The control process can handle both real-time control instructions and simulation testing without requiring separate systems.
3Reliability
If simulation devices are connected to the control device for simulation, then simulation capability is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent merges the simulation functionality directly into the existing control device architecture. The control process is modified to accept input data from either peripheral units or the computer model through the same communication connections, eliminating the need for separate simulation devices and reducing overall system complexity.
Solution Approach 2:
The control device performs simulation testing on its own control process using the computer model as an input data source. The control device iteratively processes control instructions and tests them against the process model without requiring external simulation equipment, enabling self-diagnosis and testing capabilities.
Data Source
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AI summary
The device has communication connections (7) and a control process (9) accessing input data and determining output data based on input and internal data. The control device implements a model of an industrial technical process based on simulated peripheral units, where the input data is provided to the control process, and the control process provides the output data to the model based on the simulated units. The input data is provided to the control process over the connections and the control process provides the output data for output over the connections based on the non-simulated units. An independent claim is also included for a data carrier with a computer program for a control device.