Digital Twin Test-Run Control for Battery Facility Commissioning
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Solution Overview
Problem
Existing facilities for manufacturing batteries with new specifications require extensive manual inspections and labor-intensive test-running, leading to high costs and inefficiencies, as conventional digital twin technologies lack the ability to verify automatic correction logic before equipment assembly.
Innovation Solution
A system and method utilizing a digital twin object to simulate equipment operations, incorporating automatic correction logic calculation units to determine and apply control values in a virtual world, allowing for real-world equipment verification and automatic correction software transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspections and test-running are conducted for new facilities, then equipment reliability is improved, but labor costs and time consumption increase
Solution Approach 1:
The patent creates a digital twin of the facility before physical assembly to perform virtual test-running and verify control programs in advance. This preliminary action in the virtual environment allows detection and correction of control logic errors before real equipment is assembled, reducing the need for extensive manual testing of the actual facility while ensuring reliability.
Solution Approach 2:
The patent creates a digital copy (digital twin) of the physical facility that replicates its structure, equipment, and control logic. This virtual copy enables test-running and verification without affecting the actual facility, allowing comprehensive reliability checking while eliminating time-consuming manual inspections of the real equipment.
2Reliability
If manual inspections and test-running are conducted for new facilities, then equipment reliability is improved, but labor costs increase
Solution Approach 1:
The control program is developed and verified in the digital twin environment before physical facility assembly. This preliminary development and testing in the virtual world allows manual labor to be replaced by automated simulation, improving manufacturing efficiency while maintaining equipment reliability through thorough pre-verification.
Solution Approach 2:
The patent replaces manual mechanical inspection and test-running operations with automated digital simulation. The virtual test-running system automatically executes control programs and detects errors, substituting labor-intensive manual processes with automated computational methods, thereby reducing labor costs while maintaining reliability verification.
3Manufacturing precision
If control programs are configured after equipment assembly, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The control program is configured, tested, and verified in the digital twin before physical equipment assembly. This preliminary configuration in the virtual environment ensures manufacturing precision is maintained through thorough testing, while simultaneously improving productivity by eliminating the need for post-assembly program development and debugging.
Solution Approach 2:
The patent inverts the traditional sequence by configuring and testing control programs in the digital twin before physical assembly, rather than after. This reversal allows control program development to proceed in parallel with or before equipment manufacturing, maintaining precision through virtual testing while dramatically accelerating overall facility commissioning productivity.
4Adaptability or versatility
If new facilities are manufactured for different battery specifications, then adaptability is improved, but test-running complexity increases
Solution Approach 1:
The patent creates a digital twin that can be configured to match different battery production facility specifications. This virtual copy allows testing of various facility configurations and control programs for different battery types without increasing physical test-running complexity, as all scenarios can be simulated in the adaptable digital environment.
Solution Approach 2:
The digital twin system serves multiple functions: it can simulate different facility configurations, test various control programs, verify safety systems, and evaluate performance for different battery specifications. This multi-functionality in a single virtual platform handles diverse testing requirements without proportionally increasing system complexity.
Data Source
AI summary
A system for test running of equipment using a digital twin object is presented and the system may include a controller configured to determine at least one control value for operation of at least one equipment in the virtual world; transmit an at least one control value to the equipment in the virtual world; receive at least one feedback on the at least one control value from the at least one equipment in the virtual world wherein the at least one feedback on the at least one control value is used to calculate at least one correction value for a virtual model control program; and receive the at least one correction value based on the at least one feedback on the at least one control value.