Industrial Control Loop Digital Twin for Lifecycle Integration
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Solution Overview
Problem
Existing industrial process feedback control systems lack comprehensive solutions for ease of use and integration across the entire life cycle, forcing users to employ different tools for real and virtual representations of power drive systems.
Innovation Solution
A computer-aided method for operating industrial process feedback control systems, which includes configuring the control module and controlled system, generating reference data, creating a dynamic simulation model, optimizing configuration parameters, and applying data analytics to improve control and process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If comprehensive virtual representation (digital twin) of power drive system is created including dynamic behavior throughout life cycle, then measurement precision and reliability are improved, but device complexity increases due to integration of multiple tools and systems
Solution Approach 1:
The patent merges multiple tools and systems into a unified platform that handles configuration, commissioning, operation, and analytics for both real and virtual power drive systems. This integration eliminates the need for separate tools throughout the life cycle, reducing overall system complexity while maintaining comprehensive measurement capabilities for creating accurate digital twins.
Solution Approach 2:
The control module is designed with multi-functionality to serve dual purposes: controlling the real power drive system and simultaneously updating the virtual representation (digital twin). This universal approach allows a single system to perform multiple functions including measurement, simulation, optimization, and analytics across both physical and virtual domains.
2Ease of operation
If integration of all tools is provided for ease of use and comprehensive user experience, then ease of operation is improved, but device complexity increases due to comprehensive solution architecture
Solution Approach 1:
The patent combines configuration, commissioning, operation, and analytics tools into a single integrated platform. Users can manage both real and virtual power drive systems through one unified interface, eliminating the need to switch between multiple tools and simplifying the user experience while maintaining comprehensive functionality.
3Productivity
If dynamic simulation model with physics model is used to optimize control parameters, then productivity and process efficiency are improved, but device complexity increases due to modeling and simulation requirements
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the power drive system that replicates its dynamic behavior through physics-based simulation models. This virtual model allows for optimization of control parameters without affecting the real system, enabling productivity improvements through simulation-based testing and optimization before implementing changes in the physical system.
Data Source
AI summary
A computer-aided method for operating an industrial process feedback control system is provided. The industrial process feedback control system includes a control module and a controlled system. The control module is configured to perform at least one control action to affect at least one variable/parameter of the controlled system. The control action depends on a measured value of the at least one variable.