Digital Twin Process Image Access for Adaptive Automation Control
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Solution Overview
Problem
Conventional controllers in automation systems do not provide visibility or accessibility to real-world objects, requiring programmers to manually adapt code whenever physical changes occur, leading to inefficiencies and production interruptions.
Innovation Solution
The implementation of digital twins, which are digital representations of physical devices, allows for uniform access to process image data through a process image backbone, enabling dynamic interaction and adaptation to changes in the automation system without requiring explicit code changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional controllers use static object models configured during commissioning, then the controller structure is simple and stable, but the system cannot adapt to physical changes without programmer intervention
Solution Approach 1:
The patent creates digital twins as virtual copies of physical devices and processes. These digital twins mirror the structure and behavior of physical objects, allowing the controller to interact with virtual representations rather than directly with complex physical systems. When physical devices change, corresponding digital twins are created or modified automatically, eliminating the need for programmers to manually update control logic for every physical change.
Solution Approach 2:
The patent introduces digital twins as an intermediary layer between the physical process and the controller. This intermediary layer absorbs the complexity of physical device variations, allowing the controller to work with standardized digital representations. The digital twins translate diverse physical device interfaces into uniform virtual interfaces that the controller can handle consistently.
2Productivity
If programmers manually translate and reconstruct real world objects into digital signals, then the controller can control physical devices, but any physical changes require time-consuming code modifications that interrupt production
Solution Approach 1:
Digital twins are automatically created as virtual copies when physical devices are added or modified. This automatic copying process eliminates the manual translation work that previously required programmer intervention. The controller can immediately begin interacting with new physical devices through their corresponding digital twins without waiting for code modifications.
Solution Approach 2:
The system performs self-configuration through automatic digital twin creation. When physical devices are added to the process, the system automatically generates corresponding digital twins and configures the necessary control logic, eliminating the need for external programmer intervention. This self-service capability ensures production continues uninterrupted.
3Adaptability or versatility
If the object model is statically configured during commissioning, then the initial system setup is straightforward, but the system lacks flexibility to accommodate adding, removing, or changing equipment
Solution Approach 1:
The system creates digital twins as virtual copies of physical devices. These digital twins automatically reflect the current state of physical equipment, providing a flexible representation that adapts when devices are added, removed, or modified. The controller interacts with these flexible digital representations rather than rigid static configurations.
Solution Approach 2:
The patent transforms the static object model into a dynamic system through digital twins. Digital twins can be created, modified, or deleted dynamically as physical devices change, allowing the system to adapt in real-time without requiring reconfiguration of the underlying controller architecture.
4Loss of information
If controllers expose only digital or analog inputs and outputs in the object model, then the controller interface is simple and standardized, but real world objects and assets are not visible or accessible
Solution Approach 1:
Digital twins create virtual copies of real-world objects that preserve their structural and behavioral characteristics. These digital representations make physical devices visible and accessible in the control system without exposing the full complexity of the physical interfaces. The digital twins serve as information-rich proxies that maintain simplicity at the controller interface.
Data Source
AI summary
A system for using digital twins to interact with physical objects in an automation system includes a plurality of controller devices, a process image backbone, and a registry comprising a plurality of digital twins. Each respective controller device comprises a volatile computer-readable storage medium comprising a process image area. The process image backbone provides the controllers with uniform access to the process image area of each controller. Each digital twin in the registry corresponds to a physical device controllable via one of the controllers devices via a corresponding process image area.