Digital Twin Link for Non-Digital Field Device Integration
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Solution Overview
Problem
Two-wire field devices in automation systems, which communicate via a conventional two-wire line and lack connection to the IT world, are not easily connectable to digital platforms like MES or cloud systems, limiting their digital capability.
Innovation Solution
A method to create a digital twin for non-digital field devices by connecting a unit to download data, generating a timestamp, transmitting data to the cloud, instantiating a digital image, and providing an authenticated link for execution on a computer unit, enabling IP-based communication and connection to product databases for data synchronization and change detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two-wire field devices use conventional two-wire cable communication, then device simplicity and legacy compatibility are maintained, but digital capability and connection to IT systems are lost
Solution Approach 1:
A connection unit serves as an intermediary device that interfaces between the two-wire field device and the digital network. This mediator translates analog two-wire signals into digital IP-based communication, enabling legacy devices to connect to cloud platforms and IT systems without modifying the field device itself
Solution Approach 2:
A digital twin is created as a virtual copy of the physical field device. This digital replica contains all relevant device data, parameters, and operational information, allowing the physical device to be represented and managed in the digital realm through IP-based communication networks
2Adaptability or versatility
If field devices function autonomously within the automation system, then system stability is maintained, but integration with cloud platforms and IT systems is prevented
Solution Approach 1:
The connection unit acts as a bridge that enables data exchange between the autonomous field device and external IT systems. It maintains the device's operational independence while simultaneously providing data accessibility to cloud platforms through IP-based communication
Solution Approach 2:
The digital twin receives real-time data from the field device and can send commands back through the connection unit. This feedback mechanism enables bidirectional communication, allowing the autonomous device to remain independent while being fully integrated into the digital ecosystem
3Loss of information
If digital twins are created in the cloud with full data synchronization, then data accessibility is improved, but communication overhead and complexity increase
Solution Approach 1:
Instead of duplicating entire system states, only essential device data and parameters are copied to create the digital twin. This selective copying approach maintains data accessibility while minimizing communication overhead and complexity
Solution Approach 2:
The system implements partial data synchronization by transmitting only the most critical device information to the cloud. This partial action approach provides sufficient data accessibility for IT system integration without the full overhead of complete data replication
Data Source
Figure 1
AI summary
A method for providing a digital twin (1) for a nondigital automation engineering field device (2), comprising the following method steps: a) connecting a connecting unit (3) to the nondigital field device (2); b) downloading data concerning the connecting unit (3) that are held in the nondigital field device (2); c) producing a timestamp (4) for the downloaded data; d) transmitting the downloaded data together with the timestamp to a cloud (5); e) instantiating a digital image (6) of the nondigital field device (2) in the cloud (5); f) producing and providing an authenticated link (7) for downloading the digital twin (1); g) downloading the digital twin (1); h) linking the digital twin (1) executed on the computer unit (9) to a product database located in the cloud (5); i) checking whether the product data held in the product database (10) have undergone a change in comparison with the data that were supplied to the digital image (1) at the time of the timestamp (4).