Industrial Plant Model Synchronization Using Inverse Device Models
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Solution Overview
Problem
Current methods for synchronizing simulation models with real industrial plants are labor-intensive and lack accuracy, making it difficult to achieve reliable simulation of industrial processes.
Innovation Solution
The method involves creating extended device models that use mathematical functions to simulate real device behavior, allowing for the back-calculation of input values from real output and status values using inverse functions, enabling detailed synchronization between simulation and real systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual comparison methods are used to synchronize simulation models with real plants, then the synchronization can be achieved, but the process requires significant manual input and considerable effort while lacking accuracy
Solution Approach 1:
The patent replaces manual mechanical comparison methods with an automated mathematical system. Device models with inverse functions automatically calculate and compare simulation values with real plant values, eliminating the need for manual input and significantly reducing both time and effort while improving accuracy.
Solution Approach 2:
The patent creates digital copies (device models) of real plant components that replicate their behavior through mathematical functions. These models can be fed with real values and automatically compared, providing an accurate and efficient synchronization method without manual intervention.
2Measurement precision
If detailed device models with inverse functions are implemented to improve synchronization accuracy, then the model complexity increases, but this enables automated back-calculation and reduces manual effort
Solution Approach 1:
The patent divides the plant into individual device components, each with its own device model. This segmentation allows for targeted extension of specific device models with inverse functions where needed, rather than complicating the entire system, thus managing complexity while improving accuracy.
Solution Approach 2:
The patent extends device models with inverse functions that allow back-calculation from output to input values. This inversion capability enables automated synchronization by comparing calculated values with real values, improving accuracy while the modular approach keeps overall system complexity manageable.
Data Source
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AI summary
The invention relates to a method for synchronizing a system model with a real system, the method comprising the following steps: a) a system model is provided, which comprises at least one device model (10), which is designed to calculate simulated output values and/or state values from simulated input values using mathematical functions and which is expanded with one or more mathematical functions inverse to the one or more mathematical functions, b) at least one real output value and/or state value is provided, c) the at least one real output value and/or state value is fed to the expanded device model (10), d) by means of the functions, at least one input value is calculated back from the at least one real output value and/or state value, and e) the at least one back-calculated input value and/or a derived value is used to synchronize the system model with the real system. The invention further relates to a method for operating an industrial system, to an apparatus, to a computer program product and a to computer-readable medium.