Industrial Control Simulation with Time-Stamped State Restart
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Solution Overview
Problem
Current simulation methods for industrial processes and machines require restarting from the beginning when errors occur, making troubleshooting time-consuming and resource-intensive.
Innovation Solution
A simulation system that stores and time-stamps intermediate states during simulation, allowing for restarting at any previous point, thereby reducing the need to restart from the beginning and enhancing troubleshooting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If simulation is restarted from the beginning when an error occurs, then the simulation can be troubleshooted, but the troubleshooting time is excessive and resource-intensive
Solution Approach 1:
The patent applies preliminary action by storing intermediate simulation states at regular intervals during the simulation process. When an error occurs, the system can restore to the most recent valid intermediate state rather than restarting from the beginning. This preliminary storage of state information enables efficient troubleshooting by eliminating the need to re-execute lengthy simulation sequences, directly resolving the time loss problem while maintaining full troubleshooting capability
Solution Approach 2:
The patent implements copying by creating and storing copies of the simulation system's intermediate states (including process data, control commands, and simulation parameters) at various points during execution. These state copies are saved with time stamps and can be restored when errors occur. This copying mechanism allows the simulation to be resumed from any previous valid state without re-executing the entire simulation, thereby dramatically reducing troubleshooting time and resource consumption
2Reliability
If test processing is performed on actual workpiece, then processing results can be verified, but it consumes excessive material and time
Solution Approach 1:
The patent uses copying to create a virtual copy of the workpiece and processing environment in the simulation system. The simulation processes this virtual copy using the same control program and parameters that would be used in actual processing. This allows complete verification of processing results, detection of errors, and optimization of parameters without consuming any actual workpiece material, thereby eliminating material waste while maintaining full verification reliability
Solution Approach 2:
The patent applies preliminary action by performing all processing verification and validation in the simulation environment before actual processing begins. The simulation executes the control program, applies processing parameters, and verifies results in advance. Any errors or issues are identified and corrected during this preliminary simulation phase, ensuring that when actual processing occurs, it proceeds without errors and without wasting workpiece material on failed test runs
Data Source
AI summary
Simulation methods for simulating a real control (2) for an industrial process, a plant or a machine shall be able to determine errors occurring in the course of simulation more easily. For this purpose the invention proposes that the simulation system (7) stores intermediate states during the simulation and time-stamps them, wherein a stored intermediate state can be reloaded into the simulation system (7) at a later time and a simulation carried out on the basis thereof. As a result, simulations do not always need to start with the beginning of the control program to be simulated.