Plant Operation Parameter Control Using a Learning Database
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Solution Overview
Problem
Managing the operating conditions of plants producing chemical or industrial products is challenging due to the complexity of manipulating numerous parameters and predicting changes in state parameters, which existing technologies struggle to address effectively without increasing hardware resources or processing load.
Innovation Solution
A plant management system comprising a control device that sets and acquires manipulation and state parameters, and a management device that uses a database to determine optimal parameter settings by learning from actual operations and simulating plant conditions, thereby improving operating efficiency without additional hardware costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If reinforcement learning is used to simulate complicated plant processes with various manipulation and state parameters, then the operating condition can be analyzed and predicted, but the hardware resources and processing load increase significantly
Solution Approach 1:
The patent creates a virtual copy of the plant system through a simulator that models plant processes and relationships between manipulation parameters and state parameters. This virtual model allows analysis and prediction without requiring complex hardware resources or heavy processing load on the actual plant control system. The simulator replicates plant behavior to provide useful information for improving operating conditions.
Solution Approach 2:
The patent introduces a management device as an intermediary between the control device and the operator. This management device acquires operation records, manages the database, and presents information to operators in a comprehensible manner. The intermediary handles the complex data processing and presentation tasks, freeing the control device from heavy processing loads while still providing useful information to improve plant operation.
2Manufacturing precision
If a large number of manipulation parameters are set to control plant operation, then the control precision can be improved, but it becomes difficult to understand minute-by-minute changes and predict state parameter changes
Solution Approach 1:
The patent implements feedback mechanisms where the management device acquires actual operation records including manipulation parameters and state parameters, stores them in a database, and uses this data to provide information that helps operators understand the relationships between parameters. The system feeds back useful patterns and predictions to operators, making it easier to understand minute-by-minute changes and predict future state parameter changes while maintaining control precision.
Solution Approach 2:
The patent segments the complex plant control system into distinct functional components: the control device that sets manipulation parameters, the management device that manages data and provides information, and the simulator that models plant behavior. This segmentation allows each component to focus on specific tasks, making the overall system easier to operate and understand while maintaining high control precision through coordinated operation of all segments.
3Measurement precision
If actual operation records are stored in a database for analysis, then the accuracy of determining optimal manipulation parameters can be improved, but the data storage requirements and processing time increase
Solution Approach 1:
The patent performs preliminary actions by having the management device acquire and store operation records in a database during normal plant operation. This preliminary data collection and organization is done in advance, so when optimization analysis is needed, the data is already prepared and structured for quick retrieval and analysis. This reduces the processing time required at the moment when optimal parameters are needed while maintaining high accuracy through comprehensive data storage.
Data Source
AI summary
A plant management system includes: a control device; and a management device. The control device includes: a manipulation parameter setting unit that sets values of manipulation parameters; a state parameter acquisition unit that acquires values of state parameters indicating an operating condition of the plant; and a transmitter that transmits these values to the management device. The management device includes: an acquisition unit that acquires these values; a database that stores set values of manipulation parameters and actually measured values or predicted values of state parameters when the plant is operated based on the set values, corresponding to each other; and a determination unit that determines a set value of a manipulation parameter capable of improving a value of a predetermined state parameter of the plant by referring to these values and the database.