Digital Twin Plant Modeling With Virtual Instruments for Asset Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current digital twin modeling solutions are either inaccurate and inexpensive or accurate but costly and difficult to implement, especially in complex industrial settings with varying asset performance and resource usage over time, making it challenging to optimize industrial processes effectively.
Innovation Solution
A digital twin modeling system that uses a multi-layer model constructed with layers corresponding to assets, topology, connections, and physical instruments, allowing for virtual measurements and notifications to optimize asset performance, which is scalable, affordable, and easy to use, incorporating both physical and virtual data for accurate process simulation and optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If accurate digital twin modeling is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the digital twin model into multiple hierarchical layers (physical layer, virtual layer, and hybrid layer) with each layer serving specific functions. The physical layer handles sensor data collection, the virtual layer performs simulations, and the hybrid layer integrates both. This segmentation allows complex modeling tasks to be distributed across manageable modules, improving accuracy while controlling system complexity through structured organization.
Solution Approach 2:
The patent introduces a digital twin model as an intermediary between physical assets and operational decision-making. This virtual representation mediates between physical sensor data and process optimization actions, enabling accurate monitoring and prediction without requiring direct complex interactions between physical components. The digital twin acts as a buffer that simplifies the overall system architecture while maintaining high modeling fidelity.
2Measurement precision
If comprehensive asset monitoring is implemented, then measurement precision is improved, but loss of energy increases
Solution Approach 1:
The patent applies partial monitoring by focusing measurement efforts on critical assets and parameters that have the greatest impact on process optimization. Rather than continuously monitoring all assets at maximum precision, the system selectively applies monitoring based on asset importance, operational context, and risk levels. This partial action approach maintains sufficient measurement precision for decision-making while significantly reducing overall energy consumption compared to comprehensive high-precision monitoring of all assets.
3Manufacturing precision
If virtual instruments are deployed, then quantity of substance is reduced, but manufacturing precision is improved
Solution Approach 1:
The patent creates virtual copies (digital twins) of physical instruments, assets, and processes. These virtual instruments replicate the functionality and behavior of physical counterparts in a simulated environment, enabling accurate process modeling, prediction, and optimization without requiring additional physical hardware. The virtual models capture the essential characteristics and dynamics of physical assets, providing precise insights while eliminating the need for duplicating physical measurement devices.
Data Source
AI summary
A digital twin model based plant operation and optimization is provided. Systems and methods of the solution can receive data on assets of a plant, the assets' topology, connectivity and flow and deployed physical instruments along with the measurements of the physical instruments. The solution generate a model having a plurality of layers based on the received data and provide one or more virtual instruments in the model. The solution can determine, based on a set of relationships for interactions between assets and the received measurements input into the model, one or more virtual measurement for the one or more virtual instruments and generate, responsive to a comparison with a threshold, a notification to service at least one of the assets at the plant.