Digital Twin Runtime Transition Under PLC Connectivity Errors
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Solution Overview
Problem
Transitioning a runtime system from a PLC-based platform to a digitalization platform is expensive, labor-intensive, and prone to connectivity issues, leading to downtime and inaccurate processing of real-time inputs in industrial plants.
Innovation Solution
A method and system that captures and analyzes input-output parameter values to generate knowledge graphs, simulates input parameters during connectivity errors, and processes output parameters in the digitalization platform, reducing the processing load on the controller device and ensuring seamless operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the engineering program is run in the digitalization platform, then the processing power is shifted from the controller device, but the system experiences downtime due to connectivity errors and inaccurate processing of real-time inputs
Solution Approach 1:
The patent applies preliminary action by capturing and storing input-output parameter values from the controller device before transitioning to the digitalization platform. This pre-captured data serves as a foundation for generating knowledge graphs that enable the digital twin to accurately simulate controller behavior without requiring real-time connectivity during operation.
Solution Approach 2:
The patent creates a digital twin (copy) of the controller device that replicates its behavior and processing capabilities. This digital copy runs the engineering program in the digitalization platform while maintaining functional equivalence to the original controller, thereby shifting processing power without compromising system reliability.
2Measurement precision
If the digitalization platform accurately simulates the controller device behavior, then the processing accuracy is improved, but the generation of digitalization platform requires gigantic amount of time and effort
Solution Approach 1:
The patent uses preliminary action by capturing input-output parameter values during normal controller operation before digital twin generation. This pre-captured operational data significantly reduces the time and effort required to build an accurate digitalization platform, as the system learns from actual runtime behavior rather than requiring extensive manual programming or analysis.
Solution Approach 2:
The system applies self-service by automatically generating the digital twin through machine learning from captured operational data. The controller device itself provides the training data through its normal operation, eliminating the need for external experts to manually analyze and program the digitalization platform, thereby reducing generation time and effort.
3Measurement precision
If real-time inputs are fed into the digitalization platform timely, then the execution of engineering program is accurate, but connectivity errors in network connection hamper efficient functioning
Solution Approach 1:
The patent applies beforehand cushioning by creating a buffer mechanism through the digital twin that can operate independently of real-time network connectivity. The digitalization platform maintains system operation even when connectivity errors occur, cushioning the system against the harmful effects of network failures while preserving processing accuracy.
Data Source
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AI summary
The present invention provides a method and system for seamless transition of a runtime system from a controller device (124) to a digitalization platform (110) . The method further comprises simulating, by the processing unit (202), when a connectivity error is determined to present, a second input parameter value based on an analysis of the generated input-output knowledge graph. The second input parameter value is a parameter value to be received from the plurality of sensor devices (126A-N) during execution of the engineering program. The method further comprises transmitting, by the processing unit (202), the generated at least one output parameter value to a plurality of industrial devices (108A-N) in the technical installation, to control the at least the plurality of industrial devices (108A-N).