Controller-Process Co-Simulation With Dynamic Step Synchronization
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Solution Overview
Problem
Current simulation tools for controlled machines or installations face systematic errors due to unsynchronized interaction points between the physical process and controller simulations, leading to outdated input values and reduced accuracy, especially in critical timing systems.
Innovation Solution
A device and method that dynamically adjust simulation step increments based on result times exchanged between a process simulation apparatus and a controller simulation apparatus, ensuring up-to-date input values and reducing computational burden by synchronizing simulation steps with controller interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the simulation increment is reduced to reduce systematic simulation error, then measurement precision is improved, but productivity deteriorates due to higher computational burden
Solution Approach 1:
The simulation increment is made dynamic rather than fixed. The apparatus automatically adjusts the simulation increment based on the actual execution time of controller simulation steps, allowing the increment to vary adaptively. This resolves the contradiction by enabling larger increments when controller steps execute quickly (maintaining productivity) while using smaller increments when needed (ensuring accuracy).
Solution Approach 2:
The simulation increment parameter is changed dynamically based on runtime conditions. Instead of using a constant small increment that always ensures accuracy but hurts performance, the system modifies the increment parameter adaptively according to the actual controller execution time, thus balancing accuracy requirements with computational efficiency.
2Ease of operation
If the simulation increment is fixed to obtain predictable timing behavior, then ease of operation is improved, but measurement precision deteriorates due to outdated input values
Solution Approach 1:
The system implements feedback by measuring the actual execution time of controller simulation steps and using this information to adjust the simulation increment. The apparatus continuously monitors timing information and feeds it back into the simulation control mechanism, enabling automatic adaptation that maintains both predictability and accuracy.
Solution Approach 2:
The simulation increment transitions from a static fixed value to a dynamic value that adapts based on runtime timing information. This dynamic adjustment mechanism preserves the ease of operation through automated control while eliminating the precision loss associated with fixed increments.
3Measurement precision
If the simulation increment is reduced to improve simulation accuracy, then measurement precision is improved, but device complexity increases due to higher computational burden
Solution Approach 1:
The simulation increment is made dynamic, automatically adjusting based on controller execution time. This eliminates the need for consistently small increments, thereby reducing the overall computational complexity while maintaining accuracy where necessary. The system becomes smarter rather than more complex.
Solution Approach 2:
The simulation increment parameter is dynamically changed based on runtime conditions, allowing the system to use larger increments when appropriate and smaller increments only when necessary. This adaptive parameter change reduces the average computational complexity while preserving simulation accuracy.
Data Source
AI summary
A device for simulating a controlled machine or installation includes a process simulation apparatus designed to perform simulation steps that simulate a physical process of the machine or installation, and a controller simulation apparatus designed to perform simulation steps that simulate a controller of the machine or installation. The process simulation apparatus and the controller simulation apparatus exchange particular output values so as to simulate the controlled machine or installation in the respective simulation steps. The controller simulation apparatus transmits an item of information to the process simulation apparatus, which item of information describes a result time for an end of a simulation step performed by the controller simulation apparatus, while the process simulation apparatus is designed to adjust a duration of at least one of the simulation steps depending on the result time.