Industrial Plant Evaluation Device Reducing Calculation Cost
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Solution Overview
Problem
Current industrial plant simulation devices lack a clear method for calculating manipulated variables, such as valve opening degrees, which increases calculation costs, especially when operated online.
Innovation Solution
An industrial plant evaluation device and method that receives actual machine manipulated variables, uses a process model to estimate and compare process variables, potentially smoothing or predicting these variables to reduce calculation costs without needing a controller model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a simulation device is operated online to perform industrial plant evaluation, then the evaluation can be performed in real-time, but the calculation cost increases due to the need for a controller model to calculate manipulated variables
Solution Approach 1:
The patent extracts and removes the controller model from the simulation system. Instead of using a controller model to calculate manipulated variables, the invention directly uses actual machine manipulated variables from the process control system. This extraction eliminates the unnecessary calculation component while maintaining the core evaluation functionality, thereby reducing calculation cost while preserving real-time evaluation capability.
2Measurement precision
If a controller model is used to calculate manipulated variables in the simulation, then the simulation accuracy is improved, but the device complexity and calculation cost increase
Solution Approach 1:
The patent uses actual machine manipulated variables as direct copies of the control signals from the process control system. Instead of creating a complex controller model that replicates control logic, the invention directly copies and utilizes the actual manipulated variable data. This approach maintains simulation accuracy by using real control data while significantly reducing device complexity and calculation requirements.
3Device complexity
If the actual machine manipulated variable is used directly without smoothing, then the calculation process is simpler, but the noise in manipulated variable data affects the evaluation accuracy
Solution Approach 1:
The patent applies smoothing processing as a preliminary action to the actual machine manipulated variables before they are used in the evaluation. By pre-processing the data to remove noise and fluctuations, the system ensures that the subsequent evaluation uses clean, reliable data. This preliminary smoothing action improves evaluation accuracy without significantly increasing overall system complexity, as it is a straightforward data processing step.
Data Source
AI summary
In order to reduce the calculation cost of industrial plant evaluation, an industrial plant evaluation device 5 comprises: a reception unit 51 configured to receive an actual machine manipulated variable in process control of an industrial plant and an actual machine process variable to be controlled by the process control; an estimation unit 52 configured to determine a process variable as an estimated process variable by using a process model defining a mathematical relationship between a manipulated variable and a process variable in the process control, the process variable as the estimated process variable being obtained by substituting the actual machine manipulated variable for the manipulated variable in the process model; and a comparison unit 53 configured to compare the estimated process variable and the actual machine process variable with each other.