Runtime Transition to a Digitalization Platform Under Connectivity Errors
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Solution Overview
Problem
Transitioning a runtime system from a controller device to a digitalization platform is expensive, labor-intensive, and prone to connectivity errors, leading to downtime and inefficiencies in industrial plants due to the need for accurate simulation of the controller device's behavior and timely input of real-time data.
Innovation Solution
A method and system that captures and analyzes input-output parameter values to generate knowledge graphs, allowing for the prediction and simulation of parameter values, reducing processing load on the controller device by shifting processing power to the digitalization platform, even in the presence of connectivity errors, and optimizing engineering program execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the engineering program is run in the digitalization platform, then the processing load on the controller device is reduced, but the system requires timely input of real-time inputs to avoid downtime and connectivity errors may hamper efficient functioning
Solution Approach 1:
The system performs preliminary actions by capturing and analyzing input-output parameter values before transitioning to the digitalization platform. This preparation ensures that the digital twin is pre-configured with necessary data patterns and relationships, enabling seamless transition without downtime while maintaining system reliability.
Solution Approach 2:
The patent introduces an intermediary mechanism (the digital twin with knowledge graphs) that bridges the controller device and the digitalization platform. This intermediary captures and processes data locally before migration, ensuring continuous operation and reliability during the transition, while enabling the platform to handle processing loads.
2Measurement precision
If the digitalization platform accurately simulates the controller device behavior, then processing can be shifted to the platform, but generation of the digitalization platform takes a gigantic amount of time and effort
Solution Approach 1:
The system applies partial action by initially capturing and analyzing only essential input-output parameter values and their relationships to create a functional digital twin. This partial implementation achieves sufficient simulation accuracy for operational purposes without requiring complete exhaustive analysis, thereby reducing transition time and effort while maintaining adequate precision.
Solution Approach 2:
The patent performs preliminary data capture and analysis activities before full platform transition. By pre-processing and organizing input-output parameter data in advance, the system reduces the time and effort required for generating the digitalization platform, achieving a balance between simulation accuracy and transition speed.
3Speed
If real-time inputs are not fed into the digitalization platform timely, then the execution of the engineering program is affected, but network connection errors between sensor devices and the platform can cause downtime
Solution Approach 1:
The system performs preliminary data capture and local analysis at the controller device before transitioning to the digitalization platform. This preliminary action ensures that data processing can continue locally even when network connections are interrupted, maintaining operational continuity and reliability while enabling fast local response times.
Solution Approach 2:
The digital twin acts as an intermediary that can operate independently with captured historical data when network connections fail. This intermediary maintains operational continuity by using pre-captured input-output parameter values and their relationships, ensuring reliable operation even during network disruptions while enabling rapid local decision-making.
Data Source
AI summary
A method and system for seamless transition of a runtime system from a controller device to a digitalization platform is provided. The method further includes simulating, by the processing unit, when a connectivity error is determined to present, a second input parameter value based on an analysis of the generated input-output knowledge graph. The second input parameter value is a parameter value to be received from the plurality of sensor devices during execution of the engineering program. The method further includes transmitting, by the processing unit, the generated at least one output parameter value to a plurality of industrial devices in the technical installation, to control the at least the plurality of industrial devices.