Field Device Simulation Server for Early Plant Engineering
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Solution Overview
Problem
In industrial plants, engineers face challenges in device management systems as they struggle to perform functions like system configurations and behavior checks without physical devices, and existing hardware simulators are limited in functionality and device compatibility.
Innovation Solution
A method and system that synchronizes plant network hierarchy and registered device data to a device simulation server, enabling simulation of device communication with virtual parameters and parallel communications to simulated devices, allowing for configuration and status simulation of both configurable and non-configurable device parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware simulator is used for simulation, then simulation function is provided, but device compatibility and functionality are limited
Solution Approach 1:
The simulation server is designed to simulate multiple types of field devices (analog devices, digital devices, smart devices) through a unified architecture that uses device description files to define device-specific behaviors. This allows a single simulation server to replace multiple dedicated hardware simulators, achieving universal compatibility across different device types while maintaining manageable system complexity through standardized interfaces and configuration mechanisms.
2Productivity
If physical devices are used for device engineering, then accurate behavior check-up is possible, but engineering work must wait for device availability
Solution Approach 1:
The simulation server enables engineers to perform device engineering activities (configuration, parameter setting, behavior verification) in advance using virtual simulations before physical devices are available. The system synchronizes plant network hierarchy data and registered device data to create accurate virtual representations, allowing complete engineering preparation including I/O configuration, communication parameter setting, and system integration testing to be completed beforehand, eliminating waiting time and accelerating project deployment.
3Adaptability or versatility
If device management system is coupled to physical control station, then real device communication is achieved, but simulation function is lost
Solution Approach 1:
The simulation server acts as an intermediary between the device management system and the virtual environment. It receives communication requests from the device management system and generates appropriate responses based on simulated device behaviors, mimicking real device communication protocols and data exchanges. This intermediary layer provides realistic simulation feedback without requiring physical device connections, enabling engineers to test and verify system functionality, communication protocols, and configuration settings in a controlled virtual environment while maintaining the same communication interfaces and procedures used with real devices.
Data Source
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.