Integrated Simulation System for Control Hardware
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Solution Overview
Problem
Current simulation systems for technical installations, such as power plants, are complex and decoupled from the control system, requiring separate hardware and software configurations, leading to inconsistent simulations and increased downtimes during training and testing.
Innovation Solution
An integrated simulation system where execution environments for automation, hardware peripherals, and process simulations are incorporated within the control system's software, using the same engineering tools and interfaces, merging the control system and simulator into a unified software entity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate simulation computers are used to simulate power plants, then realistic simulation can be achieved, but gigantic computer power is required and hardware must be constructed, installed and maintained at each place of use
Solution Approach 1:
The patent merges the simulation computer functionality with the control system by integrating the simulation execution environment into the control system's hardware platform. The simulation computer and control system share common hardware resources including processor, memory, and I/O interfaces, eliminating the need for separate simulation hardware at each location while maintaining realistic simulation capabilities through software-based process modeling
Solution Approach 2:
The control system hardware is designed to serve dual purposes: controlling the actual power plant during operation and executing simulation software for training and testing. The same processor, memory, and communication interfaces are used for both real-time control tasks and simulation tasks, making the hardware universal and eliminating the need for dedicated simulation computers
2Adaptability or versatility
If simulation software is decoupled from the control system, then separate configuration is possible, but configuration becomes very complex and consistency checks between simulator and control system do not take place
Solution Approach 1:
The simulation software is merged with the control system software architecture, sharing common execution environments, data structures, and configuration mechanisms. The simulation process model uses the same I/O interface definitions and process data structures as the control system, eliminating the need for separate configuration tools and procedures while enabling automatic consistency verification through shared software components
Solution Approach 2:
The patent applies homogeneity by using identical software components, data structures, and configuration approaches for both control and simulation functions. The same process control language, I/O interface definitions, and execution environment are used in both modes, ensuring configuration consistency and eliminating the need for separate configuration toolsets
3Ease of manufacture
If simulator configuration does not take into account engineering data relating to cabling or wiring, then configuration is simpler, but consistency between simulator and actual installation is compromised
Solution Approach 1:
The simulation configuration automatically inherits engineering data including cabling and wiring information from the control system configuration. The same I/O interface definitions, process connection data, and hardware configuration files are used for both control and simulation, ensuring that the simulator accurately reflects the actual installation's physical connections without requiring separate configuration efforts
Data Source
AI summary
A simulation system in particular for a control system which controls a process running in a technical system is provided. The control system has at least one first process environment embodied as a container and which is also designed to simulate the automatic process to be run in the system and includes corresponding interfaces to the guidance system. The simulation system includes, in addition to the first process environment, a second process environment embodied as a container for simulating the hardware of the periphery of the guidance system and a third process environment embodied as a container for simulating the process to be run in the technical system. In another embodiment, all process environments can also be combined to form one process environment. In both variations, the interfaces of the first process environment and the interfaces of the second process environment are practically identical to the interfaces of the third process environment. A method for carrying out a simulation, a corresponding control system, and computer program product are also provided.