Modular Process Plant Simulation from Mechanical Flows and Control Logic
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Solution Overview
Problem
Existing methods for verifying and validating automation systems in industrial processes are complex, costly, and require significant manual work, lacking an automated process to generate simulation models for process sections.
Innovation Solution
A method is provided to automatically generate a simulation model of a process section by interpreting mechanical flows and control logic, integrating them, and simulating the process using a non-volatile data storage medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual methods are used to create simulation models for process sections, then the models can be customized and adapted to specific scenarios, but the process becomes complex, time-consuming, and costly
Solution Approach 1:
The patent creates simulation models by automatically copying and integrating existing process description data and control logic from the industrial process system. Instead of manually building simulation models from scratch, the system generates simulation models by copying relevant data structures, parameters, and control relationships from the actual process system, thereby reducing model creation time while maintaining adaptability to specific scenarios
Solution Approach 2:
The patent performs preliminary actions by pre-defining process sections, their parameters, and control logic structures before actual simulation needs arise. The system prepares simulation models in advance by automatically generating them from existing process descriptions, so that when verification or validation is needed, the models are already ready for use, eliminating time-consuming manual model creation at the moment of need
2Productivity
If automated simulation model generation is implemented, then model creation time and costs are reduced, but the complexity of integrating mechanical flows and control logic increases
Solution Approach 1:
The patent segments the industrial process into distinct process sections, each with its own simulation model. By dividing the overall system into manageable segments (process sections with specific functions like mixing, heating, cooling), the system can automatically generate individual simulation models for each segment and then integrate them. This segmentation reduces the complexity of integrating mechanical flows and control logic by handling smaller, modular units rather than the entire system at once
3Reliability
If verification and validation are performed with the automation system in an evolved state, then realistic testing is achieved, but significant manual work and costs are required
Solution Approach 1:
The patent creates a copied simulation environment that mirrors the actual industrial process system. Instead of requiring physical presence of evolved automation systems for verification and validation, the system generates simulation models that copy the process behavior, control logic, and operational characteristics. This allows comprehensive verification and validation testing to be performed in the simulation environment with minimal manual effort, while maintaining high verification quality through realistic scenario testing
Data Source
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AI summary
A method (100) of simulating a process section of an industrial process is provided. The method comprises obtaining (110) a model of mechanical flows (210) within the process section; obtaining (120) a state-based control logic (320) describing interactions between equipment associated to the process section; providing (130) a simulation model for the process section based on the model of mechanical flows and the control logic; and simulating (140) the process section based on the simulation model. Providing the simulation model comprises automatically interpreting (131, 132) the model of mechanical flows and the control logic; and automatically integrating (133) interactions between the model of mechanical flows and the control logic.