Digital Installation Simulation for Scenario-Based Operator Training
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Solution Overview
Problem
Complex technical installations require extensive training for operating personnel, but traditional training methods are often impractical due to time and cost constraints, as well as the need for the installation to remain operational.
Innovation Solution
A system that generates a digital or virtual replica of a technical installation, allowing for virtual training. This system includes a base class for device-independent hardware components and a library of virtual devices that replicate the topology and functional behavior of real devices, enabling dynamic generation of a digital replica tailored to specific training scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If training is conducted on the actual installation, then training realism and relevance are improved, but installation productivity deteriorates due to operational interruptions and waiting periods
Solution Approach 1:
The patent creates a digital twin (virtual replica) of the actual installation that replicates its topology, components, and functional behavior. This copy allows trainees to interact with a realistic representation of the installation without affecting the actual system's operational status, thereby maintaining both training quality and installation productivity simultaneously
2Productivity
If a separate training center is used, then installation operational continuity is improved, but training realism and location-specific competence deteriorate
Solution Approach 1:
The digital twin serves as an intermediary between the actual installation and the trainees. It transfers the realistic operational characteristics and topological relationships of the actual installation to the training environment, enabling trainees to gain location-specific competence without physically being present at the installation or requiring the installation to be shut down
3Reliability
If training is conducted on-site, then training relevance is improved, but personnel availability for actual installation operation deteriorates
Solution Approach 1:
By creating a virtual replica of the installation, the system allows personnel to be trained on-site with full training relevance while remaining in their actual work location. The digital twin provides the realistic training experience without requiring personnel to leave the installation premises or be absent from operational duties, thus eliminating the loss of time associated with travel and on-site training interruptions
4Reliability
If a second physical installation is built for training, then training capability is improved, but cost and device complexity worsen
Solution Approach 1:
The patent replaces the mechanical/physical system of building a second actual installation with a digital/virtual system. Instead of duplicating physical equipment, the digital twin replicates the installation's topology, components, and functional behavior in software, dramatically reducing both cost and device complexity while maintaining full training capability
Data Source
AI summary
A system and method for providing a digital simulation of a technical installation, and a corresponding computer program product, wherein the digital simulation is dynamically generated such that the digital simulation is adapted to a specified training scenario. This is accomplished using a provided basic class, which implements, independently of devices, functions of elementary hardware components, and using a library of virtual devices, which deterministically simulate the topology and the functional behavior of corresponding real devices. The virtual devices have a hierarchically nested structure, such that a hierarchically higher device comprises at least one hierarchically lower device and/or at least one of the elementary hardware components.