Digital Twin Process Control for Adaptive Event-Discrete Systems
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Solution Overview
Problem
Existing real-time process control methods for manufacturing environments, particularly in distributed event-discrete systems, lack flexibility and efficiency due to rigid hierarchical tree models that cannot be modified once process control begins, making them inadequate for dynamic changes or new setups.
Innovation Solution
A method utilizing a virtual twin engine with an executable modeling software kernel that generates meta-model representations for subsystems, partitions systems into clusters, and configures routing topologies for message exchange, allowing for real-time modification and control of distributed event-discrete systems through digital twins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If hierarchical tree models are used for process control, then system structure is clearly defined, but flexibility to modify the model is lost once control starts
Solution Approach 1:
The patent implements a dynamic model repository that allows the process control model to be modified, added, or removed during runtime. The virtual twin engine can load new models, update existing ones, and unload obsolete models without requiring complete system reconfiguration, thus making the previously static hierarchical model dynamically adaptable while maintaining structural stability.
Solution Approach 2:
The patent segments the process control system into modular components including virtual twins, model repository, and event handlers. Each subsystem can be independently modeled, modified, and updated. This segmentation allows specific parts of the hierarchical model to be changed without affecting the entire system structure, resolving the contradiction between stability and flexibility.
2Adaptability or versatility
If complete recoding of hierarchical tree model is done for new setups, then system adapts to new requirements, but time and complexity increase significantly
Solution Approach 1:
The patent prepares multiple pre-configured model templates and virtual twin configurations in advance within the model repository. When a new setup is required, the system can quickly instantiate and adapt these pre-prepared models rather than creating everything from scratch. This preliminary preparation significantly reduces the time and complexity of adapting to new requirements.
Solution Approach 2:
The patent enables copying and reusing of existing virtual twin models and process control configurations. When a new setup is needed, the system can replicate existing models and modify them as needed, rather than performing complete recoding. This copying mechanism dramatically reduces modeling time while maintaining system adaptability.
3Adaptability or versatility
If hierarchical tree model is changed, then new functionalities are integrated, but complete remodeling is required
Solution Approach 1:
The patent implements dynamic model loading and unloading capabilities that allow new functionalities to be integrated by simply adding new virtual twins or event handlers to the existing model repository. The system can dynamically register new models and their event handlers without requiring complete remodeling, thus reducing complexity while maintaining adaptability.
Solution Approach 2:
The patent creates a universal model repository and virtual twin framework that can accommodate multiple functionalities through a common architecture. Different process control scenarios, subsystems, and functionalities can be integrated using the same underlying framework, reducing the need for separate modeling efforts and decreasing overall modeling complexity.
4Productivity
If digital twins operate in passive manner with real-time access, then control efficiency improves, but system complexity increases
Solution Approach 1:
The patent introduces an event handler as an intermediary layer between the virtual twin and the physical system. The event handler manages real-time data exchange and control commands, allowing the virtual twin to operate efficiently without directly increasing system complexity. This intermediary abstracts the complexity while maintaining real-time control efficiency.
Data Source
AI summary
The present invention relates to the field of real time process control using digital twins. In more detail, the present invention relates to the field of modeling distributed event-discrete systems using digital twins and subsequent use of the models for real time control of distributed even-discrete systems. There is provided a virtual twin engine for control of a distributed even-discrete system in real-time. The virtual twin engine has installed at least one executable modeling software kernel which runs subsystem use models in relation to subsystem clusters of the distributed event-discrete system. Also, the virtual twin engine operates the at least one digital twin in a passive manner through real time access to the modeling software kernel modeling the subsystem use model of the at least one digital twin.