Field Device Simulation Server for Parallel Plant Engineering
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Solution Overview
Problem
In industrial plants, engineers face challenges in device engineering due to the lack of effective simulation tools for field device communication, particularly for various types of devices, as existing hardware simulators support only limited functions and devices, making it difficult to configure and check device compatibility without physical devices.
Innovation Solution
A method and system that synchronize plant network hierarchy and registered device data to a simulation server, enabling simulation of device communication with virtual parameters for configurable and non-configurable device parameters, and device status, allowing parallel communication with simulated devices, thus facilitating device engineering without physical field devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware simulator is used for simulation, then simulation function is provided, but device type limitation occurs and only particular devices can be simulated
Solution Approach 1:
The patent implements a universal simulation server that can simulate multiple types of field devices (analog devices, digital devices, smart devices) through a unified architecture. The server uses standardized device description files and parameter structures to accommodate different device types, eliminating the need for separate hardware simulators for each device type while maintaining comprehensive simulation capabilities.
Solution Approach 2:
The patent creates virtual copies of physical field devices through device description files that contain parameter definitions, data structures, and communication protocols. These virtual device models replicate the behavior and characteristics of actual devices, enabling simulation without requiring physical hardware while maintaining device-specific functionality.
2Productivity
If physical field devices are used for device engineering, then actual device behavior can be tested, but engineering work must wait for device availability causing time loss
Solution Approach 1:
The patent enables engineers to perform device engineering activities in advance using virtual device simulations. Configuration, parameter setting, and communication testing can be completed before physical devices are available, allowing engineering work to proceed parallel to device procurement and installation scheduling.
Solution Approach 2:
The simulation server acts as an intermediary between the device management system and physical field devices. It provides a virtual interface that mimics actual device behavior, allowing engineers to test and configure systems without direct access to physical devices, thereby eliminating waiting time while maintaining engineering accuracy.
3Adaptability or versatility
If hardware simulator supports limited functions, then device simulation is possible, but comprehensive device management functions cannot be carried out
Solution Approach 1:
The simulation server is designed to provide comprehensive device management functions including configuration, monitoring, diagnostics, and communication testing across all device types. It implements a complete device lifecycle management capability within a single unified platform, replacing multiple specialized hardware simulators.
Solution Approach 2:
The patent segments the simulation functionality into modular components: device description file parsers, virtual device instances, communication protocol handlers, and parameter management modules. This modular architecture enables comprehensive functionality while maintaining system manageability and ease of extension for additional device types.
Data Source
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AI summary
In a device engineering method, data of a plant network hierarchy (PNH) and registered devices (RD) in a device management server are synchronized to a device simulation server (SS). In a simulation mode, at least one function of device management system is executed via communicating with simulated devices (SD), while the device management system being not communicatively coupled to any physical control station configured to control physical field devices in a real plant. Virtual parameters are introduced into the SD. For device configuration, simulation is made of configurable device parameters; non-configurable device parameters; and device status, with SD generated from DD files in the PNH for the RD in the FDCS. Parallel communications including sending communication requests from a CRH component to the SD in the PNH from the CRH component in the FDCS to the SD in the PNH are executed simultaneously.