Digital Twin Plant Data Testing for IoT Program Debugging

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Solution Overview

Problem

Current data processing technologies face challenges in debugging and testing upload and download programs for IoT systems, as these processes require real plant data and can only be conducted within the plant, limiting efficiency and accuracy.

Innovation Solution

A data processing system utilizing a digital twin to simulate plant equipment and technical processes, allowing for the creation of a virtual data transmission apparatus that sends data to a virtual processing apparatus, enabling program debugging and testing outside the plant through a digital twin and virtual processing apparatus connected to a cloud system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If programs are tested in a real plant using real data, then testing accuracy is improved, but testing convenience and development efficiency deteriorate

Engineering Contradiction:
Improvetesting accuracyVSAvoidtesting convenience
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The patent creates a digital twin that copies the real plant's equipment, processes, and data characteristics into a virtual environment. This virtual copy enables program testing with realistic data without requiring physical presence in the plant, thus maintaining testing accuracy while improving convenience. The digital twin replicates sensor data, equipment states, and process parameters that can be used for comprehensive program validation.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The digital twin serves as an intermediary between the real plant and the testing environment. It mediates by providing virtual data that mimics real plant conditions, allowing developers to test programs remotely with data that accurately reflects real-world scenarios, thereby resolving the contradiction between testing accuracy and convenience.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If programs are tested only on real machines in the plant, then data authenticity is improved, but testing flexibility and accessibility deteriorate

Engineering Contradiction:
Improvedata authenticityVSAvoidtesting flexibility
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

By copying the authentic plant data characteristics and equipment behaviors into the digital twin, the system maintains data authenticity while enabling testing on various virtual platforms. The digital twin preserves the statistical properties, data distributions, and operational patterns of real plant data, allowing flexible testing scenarios without compromising authenticity.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The digital twin creates a universal testing environment that can be accessed from multiple locations and configured for different testing scenarios. It provides a multi-functional platform that supports various program types, testing conditions, and access methods, thereby improving flexibility and accessibility while maintaining data authenticity through faithful replication of plant characteristics.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Ease of operation

If mock data is used for testing, then testing convenience is improved, but data representativeness and testing effectiveness deteriorate

Engineering Contradiction:
Improvetesting convenienceVSAvoiddata representativeness
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

Instead of using manually created mock data, the digital twin automatically copies and generates test data that reflects real plant conditions. This approach maintains testing convenience through automated data generation while ensuring data representativeness by replicating the statistical properties, distributions, and operational patterns of actual plant data, thereby overcoming the limitations of traditional mock data approaches.

Inventive Principle:
Principle #26Copying

Data Source

PatentEP3836049B1Data processing system and method, storage medium and computer program product
Publication Date: 2023.12.20 SIEMENS AG
  • EP3836049B1 patent drawingFigure 1~2
  • EP3836049B1 patent drawingFigure 3
  • EP3836049B1 patent drawingFigure 4

AI summary

A data processing system and method, a storage medium and a computer program product. The data processing system comprises: a first simulation unit (22) configured to generate a digital twin of at least one of a plant device and a process flow; and a second simulation unit (24) configured to generate a virtual processing apparatus for causing the virtual processing apparatus to receive first data related to the operation of the digital twin and coming from the digital twin, and to transmit the received first data to a cloud system. The invention solves the problem of inconvenient debugging or testing of related programs in plant data processing.