Digital Plant Simulation for Scenario-Based Operator Training
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Solution Overview
Problem
Complex technical systems pose challenges for effective and efficient training of operating personnel due to impracticality of using the actual system for simulation, high costs, and difficulties in replicating plant-specific training without significant effort, leading to suboptimal training methods that may compromise safety and efficiency.
Innovation Solution
A system and method for creating a digital replica of a technical plant using a computer-readable data storage device with a base class and virtual device library, allowing dynamic generation of a digital twin tailored to specific training scenarios, incorporating hierarchical structure and behavioral scripts for realistic simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If training is conducted on the actual system, then training realism is improved, but system productivity deteriorates due to operational interruptions and waiting times
Solution Approach 1:
The patent creates a digital twin that replicates the physical system's behavior, topology, and functional characteristics. This virtual copy enables realistic training scenarios without interrupting the actual system operations, as training activities occur entirely in the virtual environment while the physical system continues productive work
Solution Approach 2:
The system separates training functions from production functions by creating distinct virtual and physical environments. The digital twin handles all training-related operations independently, allowing personnel to be trained without removing them from the actual plant, thus maintaining both training quality and system productivity
2Ease of operation
If a separate training center is established, then training can occur independently, but training effectiveness deteriorates due to lack of plant-specific realism
Solution Approach 1:
Instead of creating a physical duplicate facility, the system creates a virtual copy of the specific plant through automated data collection and modeling. This digital twin captures the exact topology, devices, and operational characteristics of the target plant, providing plant-specific realism without requiring physical replication or personnel absence from the actual facility
3Reliability
If comprehensive system replication is implemented, then training realism is improved, but device complexity and implementation effort increase
Solution Approach 1:
The system automates the model generation process by automatically collecting data from the physical system through integrated data sources, generating the digital twin model without manual intervention. This self-serve approach eliminates the need for complex manual modeling efforts while achieving comprehensive system replication, as the system generates its own training environment automatically
Solution Approach 2:
The system transforms complex physical system characteristics into virtual parameters and data structures that can be processed computationally. By changing the representation from physical components to digital parameters, the system achieves comprehensive replication while reducing implementation complexity through automated data transformation and model generation
Data Source
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AI summary
The invention relates to a system (1) and to a method (S1-S12) for providing a digital simulation of a technical installation, and to a corresponding computer program product (1, S1-S12). According to the invention, 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 (3), and using a library of virtual devices (2, 12, 19, 20), which deterministically simulate the topology and the functional behavior of corresponding real devices. The virtual devices (2, 12, 19, 20) have a hierarchically nested structure, such that a hierarchically higher device (2, 12, 19) comprises at least one hierarchically lower device (20) and/or at least one of the elementary hardware components (3).