PEA Module Alarm Chain Detection Through Virtual Fault Simulation
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Solution Overview
Problem
In modular production installations, manual determination and conversion of alarm chains by manufacturers are time-consuming and error-prone, hindering efficient alarm management and automation, especially during retrofitting and changes in installation structure.
Innovation Solution
A method and system for automated alarm management using a programmable controller and simulation platform to virtually simulate fault scenarios, log alarm signals, and identify alarm chains, allowing for automatic detection and logging of alarm chains in a standardized format, reducing manual analysis and enabling manufacturer-independent operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual determination and conversion of alarm chains by manufacturers is used, then alarm chains can be determined according to standard, but the process is time-consuming and error-prone
Solution Approach 1:
The patent uses a digital twin (virtual model) of the production installation to automatically generate alarm chains. The virtual model replicates the real installation's structure and behavior, allowing automated extraction of alarm chains without manual tracing, thereby eliminating time consumption and human errors while maintaining accuracy.
Solution Approach 2:
The patent replaces the manual mechanical process of tracing alarm chains with an automated computer-based system. The evaluation unit automatically evaluates alarm-relevant data from the virtual model and generates alarm chains, substituting human expert knowledge and manual tracing with automated algorithms and data processing.
2Reliability
If manual tracing of alarm chains is performed, then complete alarm chains can be identified, but the complexity of the process increases
Solution Approach 1:
By using a digital twin that replicates the real production installation, the system automatically captures complete alarm chains through virtual commissioning and fault scenario simulations. This eliminates the need for complex manual tracing processes while ensuring completeness, as the virtual model inherently contains all alarm chain information.
Solution Approach 2:
The virtual model performs self-evaluation through automated fault scenario execution and alarm chain extraction. The evaluation unit automatically processes alarm-relevant data without requiring external expert intervention, thereby reducing process complexity while maintaining reliability through systematic automated evaluation.
3Productivity
If automated simulation and detection is implemented, then alarm chains are detected faster and more accurately, but system complexity increases
Solution Approach 1:
The digital twin serves as a virtual replica that enables automated simulation of fault scenarios and automatic detection of alarm chains. This copying approach accelerates detection speed significantly compared to manual methods, while the system complexity is managed through standardized virtual commissioning procedures and automated evaluation algorithms.
Data Source
AI summary
To automate alarm management in modular production installations, provided is, with respect to a modular production installation, for which, for its modular, manufacturer-independent construction and operation, “process equipment assembly” modules, controlled by a programmable PEA controller and simulated by means of a configurable PEA simulation, are integrated into the production installation, by means of a “module type package <MTP>” mechanism for the PEA module description, in the course of a process orchestration which is standardized the following is carried out in the alarm management: —all states of the modular production installation with respect to triggered faults of possible fault cases of the production installation are virtually run through and simulated; —simulation faults that occur are logged concomitantly by means of alarms, which provide identification and an alarm message log is created and/or alarm chains are identified and alarm relationships in the alarm chains are determined.