Digital Twin Automation Engineering for Parallel Commissioning
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Solution Overview
Problem
Existing automation systems for process plants require frequent toggling between simulation and engineering, leading to inconsistencies and parameterization errors, which can affect the real plant if not managed properly.
Innovation Solution
The automation system allows for the coexistent simulation, emulation, or virtualization of automation system components as an integral part of the hardware configuration engineering, using virtual components that can be generated, configured, and optimized in parallel with real components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation and engineering are performed separately with toggling between them, then simulation can be performed, but inconsistencies and parameterization errors occur
Solution Approach 1:
The patent merges simulation and engineering into a single integrated environment by virtualizing hardware components directly within the engineering system. Virtual components (digital twins) are created and configured alongside real hardware components in the same engineering workspace, eliminating the need to toggle between separate simulation and engineering environments. This integration ensures consistency because both virtual and real components are parameterized and configured together in real-time, preventing parameterization errors that arise from separate workflows.
2Adaptability or versatility
If virtual components are integrated into hardware configuration engineering, then coexistent simulation and engineering are enabled, but system complexity increases
Solution Approach 1:
The patent creates virtual copies (digital twins) of hardware components that can be instantiated and configured in the engineering environment. These virtual components are simplified representations that mirror the structure and parameters of real hardware but can be freely manipulated without physical constraints. The copying approach allows multiple virtual instances to coexist with real components, enabling flexible simulation and configuration while managing complexity through standardized virtual component templates.
Solution Approach 2:
The patent introduces a virtualization layer that acts as an intermediary between the physical hardware and the engineering software. This intermediary layer provides standardized interfaces and abstraction mechanisms that simplify the integration process. The virtual components serve as mediators that bridge simulation and engineering workflows, allowing seamless interaction while hiding the underlying complexity of direct hardware-simulation integration.
3Reliability
If digital twins are used for commissioning, then secure and flexible commissioning is achieved, but time and resources are required for creating and managing digital twins
Solution Approach 1:
The patent enables preliminary configuration and testing of virtual components before real hardware is deployed or commissioned. Digital twins can be created, parameterized, and tested in advance within the integrated engineering environment, allowing commissioning activities to be prepared beforehand. This preliminary action reduces on-site commissioning time and ensures that configurations are validated before being applied to physical systems, improving safety while efficiently utilizing preparation time.
Solution Approach 2:
The system enables self-service commissioning through automated validation and consistency checking mechanisms. The integrated environment automatically detects parameterization errors and inconsistencies between virtual and real components, reducing the need for manual verification. This self-service approach minimizes the time and expertise required for managing digital twins while maintaining high reliability through automated quality assurance.
Data Source
AI summary
A method for engineering an automation system that is usually tested before being put into operation, wherein a “twin” or a virtual component is generated and loaded onto a server for each real component to perform the function of the real components in a simulated manner in place of said real components, such that it is thus possible for a user to replace various real components with virtual components during the engineering process and to check or simulate the function of the automation system, where it becomes possible to perform a synchronous optimization of automation systems or to put automation programs and system displays into operation in a coexistent, safe, flexible, and incremental manner.