Controller Program Digital Twin for Automated Error Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In industrial plants, engineering programs often contain numerous programmatical errors that can force controller devices into an error state, leading to unplanned downtime and requiring extensive manual debugging, which is time-consuming and labor-intensive.
Innovation Solution
A method and system that utilize a processing unit to capture and analyze input-output signals, generate knowledge graphs, and simulate the execution of engineering programs to predict and correct errors using a digital twin and artificial intelligence models, thereby automating the detection and eradication of programmatical errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual debugging and validation is performed by code developers, then programmatical errors can be detected and corrected, but the process becomes extremely time-consuming and labor-intensive due to the huge number of programming blocks and enormous code length
Solution Approach 1:
The patent replaces manual mechanical debugging processes with automated computational systems. A processing unit executes automated validation of engineering programs by analyzing programming blocks and detecting programmatical errors without human intervention, thereby eliminating the time-consuming manual review process while maintaining comprehensive error detection coverage.
Solution Approach 2:
The patent creates a digital copy or model of the engineering program execution environment to validate programs before deployment. By simulating program execution and analyzing behavior in a virtual environment, the system can detect errors without requiring extensive manual testing of the actual control system, significantly reducing validation time.
2Reliability
If code developers manually review and validate engineering programs, then programmatical errors can be identified, but the complexity and enormous code length make it impossible to complete thorough debugging in time
Solution Approach 1:
The patent substitutes manual code review processes with automated computational validation. The processing unit systematically analyzes all programming blocks and code structures, ensuring thorough validation quality while operating at speeds impossible for human developers, thus resolving the contradiction between validation quality and development speed.
Solution Approach 2:
The patent performs automated validation and error detection as a preliminary step before program deployment or execution. By validating the engineering program in advance using automated systems, comprehensive error identification is achieved without delaying the subsequent deployment process, thereby maintaining both high validation quality and fast development cycles.
3Reliability
If extensive manual debugging is performed to eradicate programmatical errors, then controller devices can be prevented from entering error states, but the process requires huge amounts of labor and time that may make code development impossible to complete on schedule
Solution Approach 1:
The patent replaces complex manual debugging processes with automated computational validation systems. The processing unit systematically analyzes programming blocks, detects errors, and validates program correctness without requiring complex manual intervention procedures, thereby maintaining controller stability while simplifying the overall debugging process.
Solution Approach 2:
The patent enables the engineering program validation process to be self-performing through automated systems. The processing unit independently executes validation routines, analyzes code for errors, and generates validation results without requiring human labor or complex manual procedures, thus achieving reliable error prevention while reducing process complexity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention provides a method and system for eradicating programmatical errors in engineering programs for a controller device (124). The method comprises capturing, by a processing unit (202), a plurality of input-output signals associated with a controller device (124). Further, the method comprises simulating, by the processing unit (202), a plurality of input signals which are predicted to be received by the controller device (124) during a future scan cycle of execution of the engineering program. The method further comprises predicting an error state in the controller device (124)in the future scan cycle, by execution of the engineering program in a digital twin (126) of the controller device (124). The method further comprises generating corrected engineering program by application of an Artificial intelligence model on the engineering program.