Modular Production Alarm Chains via Virtual Fault Simulation
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Solution Overview
Problem
Manual alarm chain determination and recording in modular production systems are time-consuming and prone to errors, especially when system structures change frequently, hindering efficient alarm management and automation.
Innovation Solution
An automated method and system for managing alarms in modular production systems, utilizing a 'Module Type Package' mechanism to integrate PEA modules into a standardized process orchestration, which virtually triggers and simulates error scenarios, logs and analyzes alarm messages, and identifies alarm chains, thereby automating the alarm management process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alarm chain determination and recording is performed, then alarm management can be implemented, but it is time-consuming and prone to errors
Solution Approach 1:
The patent creates a virtual copy of the production plant including virtual PEA modules, controllers, and simulation models. This virtual replica allows automated simulation of error scenarios and automatic generation of alarm chains without manual intervention, thereby improving accuracy while reducing time consumption
Solution Approach 2:
The system enables self-service by automatically simulating error cases, logging alarm messages, and generating alarm chains without human operators. The virtual plant autonomously executes test scenarios and extracts alarm information, eliminating manual determination processes
2Adaptability or versatility
If system structure changes frequently, then adaptability is improved, but alarm management becomes more difficult
Solution Approach 1:
The patent implements dynamic adaptation by automatically updating the virtual plant model when the real system structure changes. The system continuously synchronizes the virtual representation with actual system modifications, allowing alarm management to adapt automatically to structural changes without increasing operational complexity
Solution Approach 2:
The system performs preliminary simulation of error scenarios in the virtual plant before changes affect the real system. This allows potential alarm management issues to be identified and resolved in advance, maintaining simplicity even as system structure becomes more flexible
Data Source
AI summary
In order to automate alarm management for the managing of alarms in modular production installations, the invention proposes that, with respect to a modular production installation (PRAL), e.g. an industrial automation installation, for which, for its modular, manufacturer-independent construction and operation, "process equipment assembly" modules (PEA-MD), controlled by a programmable PEA controller (PEA-ST) and simulated by means of a configurable PEA simulation (PEA-SM), are integrated into the production installation (PRAL), by means of a "module type package <MTP>" mechanism (MTP-MC) for the PEA module description, in the course of a process orchestration (PO) which is standardized, more particularly standardized in accordance with the standard VDI/VDE/NAMUR 2658, the following is carried out in the alarm management: - all states of the modular production installation with respect to triggered faults (FHL) of possible fault cases (FHLF) of the production installation are virtually run through and simulated; - simulation faults (SMF) that occur are logged concomitantly by means of alarms, which provide identification, e.g. by signaling, and which are in the form of alarm messages (AM), and an alarm message log (AMP) is created and/or alarm chains (AMK) are identified and alarm relationships (AZH) in the alarm chains (AMK) are determined.