Plant Control Simulation for Automatic Command Approval
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Solution Overview
Problem
Current plant monitoring control devices burden operators with the need to manually determine whether to implement control commands, especially when simulation results are unclear or when control actions other than setting value changes are required, such as valve operations or motor start/stops, without predicting the outcomes of these actions.
Innovation Solution
A plant monitoring control device that includes a simulator which predicts plant data changes after control commands are input, and automatically determines whether to implement the control, reducing operator burden by notifying the process control device of the control information only when the simulator confirms a favorable outcome.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually determines whether to implement control commands based on simulation results, then the control decision accuracy is improved, but the operator burden and decision time increase
Solution Approach 1:
The system enables self-service automation where the determination unit automatically decides whether to implement control commands based on simulator predictions, eliminating the need for operator intervention in routine decisions. The system serves itself by autonomously comparing predicted plant data with target values and executing controls without human burden.
Solution Approach 2:
The system implements feedback by continuously monitoring simulator prediction results and using this information to automatically determine control implementation. The feedback loop compares predicted outcomes with desired targets and automatically adjusts control execution, improving decision accuracy while reducing operator involvement.
2Adaptability or versatility
If the simulator predicts all control commands including valve operations and motor start/stops, then the prediction comprehensiveness is improved, but the system complexity increases
Solution Approach 1:
The simulator is designed with universal functionality to handle multiple types of control commands including setting value changes, valve operations, and motor start/stops. This multi-functionality allows the single simulator to predict outcomes for diverse control actions without requiring separate prediction systems for each control type.
Solution Approach 2:
The system manages complexity by changing parameters dynamically - the determination unit selectively applies prediction based on control command types and current plant states. Not all controls require simulator prediction, and the system adjusts its prediction scope based on operational context, reducing unnecessary computational complexity while maintaining comprehensive coverage where needed.
3Manufacturing precision
If the operator monitors multiple confirmation buttons and performs multiple operations, then the control precision is improved, but the operation time and burden increase
Solution Approach 1:
The simulator performs preliminary action by predicting control outcomes before the operator executes the control command. This advance prediction provides the operator with forecasted plant data changes, allowing informed decision-making without requiring multiple confirmations during the actual control execution, thus reducing operation time while maintaining precision.
4Productivity
If automatic determination of control implementation is implemented, then the productivity is improved, but the automation extent increases system complexity
Solution Approach 1:
The automation system is segmented into distinct functional units: the simulator for prediction, the determination unit for decision-making, and the control execution unit for implementation. This segmentation allows automatic determination to improve productivity without overwhelming system complexity, as each segment handles a specific task independently and can be developed or modified separately.
Data Source
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AI summary
A plant monitoring control device (100) is such that when a control command is input by an operator into a process control device (300) that implements control of a plant (200), a simulator (2) is notified by a control unit (13) of control information in the control command. Furthermore, whether or not to implement the control is automatically determined by a determination circuit (131) of the control unit (13) based on a result of a predictive operation by the simulator (2), and when determining to implement, the process control device (300) is notified by the control unit (13) of the control information in the control command.