Process Configuration Simulation for Reconfigurable Instrumentation
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Solution Overview
Problem
In the chemical engineering field, identifying the correct process configuration to achieve desired product yield and quality is challenging due to reliance on trial and error and initial equipment constraints, often resulting in unsuccessful set-ups and high implementation costs.
Innovation Solution
A method and system for process generation and simulation using reconfigurable instrumentation, where commands and constraints are defined, a simulation engine executes these commands based on mathematical models, and a process historian records results, allowing for simulation and mapping of process configurations onto real-world instrumentation to test and refine processes without actual real-world testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional trial and error methods are used to identify process configurations, then engineers can find suitable process set-ups, but the process requires many iterations and high implementation costs
Solution Approach 1:
The patent applies preliminary action by implementing a simulation engine that allows process configurations to be tested and validated in a virtual environment before actual implementation. The system defines commands and constraints for reconfigurable instrumentation, creates a digital model of the process, and performs preliminary simulations to identify optimal configurations, thereby avoiding trial-and-error in the physical world and reducing both time and costs.
2Reliability
If traditional trial and error methods are used to identify process configurations, then engineers can find suitable process set-ups, but implementation costs are high due to repeated modifications
Solution Approach 1:
The patent applies the copying principle by creating a virtual copy of the physical process system through a simulation engine. This digital twin allows configurations to be tested, validated, and optimized in the virtual environment before implementing changes in the physical system, thereby eliminating the need for expensive repeated trial-and-error modifications of actual equipment.
3Ease of manufacture
If reconfigurable instrumentation is used with simulation engine, then process configurations can be tested and optimized in advance, but the system complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing physical trial-and-error testing with computational simulation. Instead of physically reconfiguring and testing equipment, the system uses a simulation engine with mathematical models to virtually test configurations, substituting mechanical/physical experimentation with computational analysis, thereby reducing physical system complexity while maintaining testing capability.
Data Source
AI summary
Commands and constraints of reconfigurable instrumentation that execute unit operations of processes can be defined. A simulation engine configured to execute commands of the reconfigurable instrumentation can be defined such that processes can be simulated based on pre-defined mathematical models. A process historian configured to monitor and record results of the simulation can be defined. A first process can be simulated based on a first process configuration. The first process configuration can be mapped onto real-world reconfigurable instrumentation within the first process configuration.