Digital Twin Process Control With Event-Driven State Machines
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Solution Overview
Problem
Current digital twin applications in process control, such as in manufacturing and healthcare, face challenges in efficiently and accurately achieving process objectives due to limitations in utilizing real-time data for effective control.
Innovation Solution
Implementing an event-driven process control system within a digital twin domain that uses state machine models to model the behavior of process entities, with a controller service module asynchronously receiving event data, distributing it to a process cycle buffer, and triggering external control commands based on state machine operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If digital twins gather extensive real-time data, then data availability for process control is improved, but the efficiency and accuracy of process control remains insufficient
Solution Approach 1:
The patent segments the monolithic digital twin system into modular controller service modules, each handling specific control functions. This segmentation allows parallel processing of different control tasks, improving overall process control efficiency while maintaining comprehensive data gathering capabilities.
Solution Approach 2:
The patent implements preliminary action by pre-configuring state machine models and control logic within the digital twin domain before actual process execution. This allows the system to rapidly respond to real-time data without computational delays during critical control moments.
2Productivity
If digital twins are used for process control, then operational efficiency can be enhanced, but the system complexity increases
Solution Approach 1:
The patent introduces an event-driven architecture as an intermediary layer between data gathering and control execution. Event data from the process domain triggers specific controller service modules, which then execute appropriate control actions. This intermediary structure manages system complexity by providing clear event-handling protocols and modular service interfaces.
Solution Approach 2:
The patent implements universal controller service modules that can handle multiple types of control tasks through a common event-driven framework. These modules use standardized interfaces and can be configured for different process entities, reducing overall system complexity through reuse rather than requiring separate specialized systems.
3Manufacturing precision
If state machine models are executed in digital twin domain, then control accuracy is improved, but processing time increases
Solution Approach 1:
The patent implements periodic action by executing state machine models at discrete event triggers rather than continuously. The event-driven architecture processes state transitions only when relevant events occur, maintaining control accuracy through thorough state evaluation while minimizing processing time by avoiding unnecessary continuous computation.
Data Source
AI summary
The present invention aims at providing an approach to digital twin-based process control for efficient and accurate achievement of process objectives. Heretofore, a controller service module (18) runs an event-driven control process in a digital twin domain for control of process entities operated in a process domain. The behavior of process entities is modeled through execution of state machine models. Event data is communicated asynchronously to the controller service module (18) for storage in a process cycle buffer (26). A model-based process controller (24) reads input information in processing cycles and controls process entities by operating state machine models to reflect the input of event data. It is checked whether the operation of state machine models triggers the generation of external control commands which are then output by an outbound interface (32) to process entities for control processing.