Digital Twin Detail Control for Brownfield Plant Adaptation
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Solution Overview
Problem
The high effort required to create digital twins for operational technical plants, especially in brownfield scenarios with small batch sizes, hinders their use for analysis and adjustment, particularly in small and medium-sized enterprises.
Innovation Solution
A computer-implemented method for automatically generating a digital twin with adequate detail levels by analyzing control unit source code to determine the necessary level of detail for each plant component, using a model library to provide a digital twin suitable for hardware-in-the-loop scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a digital twin is created with high level of detail for operational plants, then the analysis and adjustment capability is improved, but the modeling effort and cost increases significantly
Solution Approach 1:
The patent applies partial action by creating digital twins with only the necessary level of detail required for specific analysis tasks, rather than creating complete high-fidelity models. The system automatically determines the sufficient level of detail based on the analysis requirements, implementing only that portion of the model needed, thus reducing modeling effort while maintaining adequate analysis capability.
Solution Approach 2:
The patent changes the parameter of model detail level dynamically based on analysis requirements. Instead of using a fixed high level of detail, the system adjusts the detail level parameter automatically according to what is sufficient for the specific analysis task, thereby reducing unnecessary modeling effort while preserving analysis quality.
2Measurement precision
If a digital twin is created with high level of detail, then the accuracy of analysis results is improved, but the complexity of model generation increases
Solution Approach 1:
The system implements partial action by generating only the necessary level of model detail required for accurate analysis, avoiding the complexity of complete high-fidelity models. The automatic determination of sufficient detail level ensures that only essential model components are created, reducing generation complexity while maintaining analysis accuracy.
Solution Approach 2:
The system applies self-service through automatic determination of the sufficient level of detail. The method autonomously analyzes requirements and generates an appropriate model detail level without requiring expert intervention to decide on model complexity, thereby reducing the complexity of model generation while preserving analysis accuracy.
3Loss of time
If a generic digital twin template is used, then the modeling effort is reduced, but the adaptability to specific plant requirements decreases
Solution Approach 1:
The patent applies dynamics by making the digital twin model adaptable and configurable for different plants and analysis scenarios. Rather than using a static generic template, the system dynamically adjusts the model detail level and configuration based on specific plant requirements and analysis needs, achieving both reduced modeling effort and maintained adaptability.
Solution Approach 2:
The system changes parameters automatically based on specific plant requirements. The method determines the sufficient level of detail and model configuration parameters dynamically according to the specific plant being analyzed, allowing generic templates to be adapted efficiently to specific cases without requiring extensive manual customization.
4Productivity
If complete digital twins are created for every plant, then the analysis capability is comprehensive, but the cost and effort for small and medium-sized enterprises becomes prohibitive
Solution Approach 1:
The patent applies partial action by creating digital twins with only the necessary level of detail for each specific analysis task, rather than creating complete comprehensive models. This approach maintains adequate analysis capability for SMEs by implementing only the essential model components needed for their specific needs, significantly reducing cost and effort.
Solution Approach 2:
The system changes the model detail level parameter automatically based on analysis requirements and plant characteristics. For SMEs with limited resources, the method determines a sufficient but reduced level of detail that maintains analysis capability while making the cost and effort affordable and manageable.
Data Source
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AI summary
The invention relates to a computer-implemented method for analyzing and/or adapting the operation of a technical system (3) comprising a number of system components (31, 32) and a control unit (4) for controlling the technical system. The method comprises: obtaining (S10) source code (42) of a control functionality executed on the control unit and extracting code artifacts from the obtained source code; performing (S20) an analysis of the extracted code artifacts and determining a sufficient level of detail for a model to model each of the system components based on the analysis performed; and providing (S30) a digital twin (5) of the technical system for use in analyzing and/or adapting the operation of the technical system, which comprises a model (51, 52) generated for each of the system components according to the respective determined level of detail.The creation of unnecessarily detailed digital clamps is avoided, so that even with small batch sizes, adjustments to plant operation using digital twins become possible.