AI Image Analysis for SCADA Digital Twin PLC Tag Mapping
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Solution Overview
Problem
Connecting programmable logic controller (PLC) data tags to three-dimensional (3D) digital twin models in supervisory control and data acquisition (SCADA) systems is difficult, requiring significant coding effort and resources, especially in variable industrial environments, and is challenging for users without programming knowledge.
Innovation Solution
A SCADA system utilizing artificial intelligence (AI)-based image analysis to recognize objects, match them with pre-stored 3D digital twin models, and connect corresponding PLC data tags, enabling real-time data application to these models for dynamic digital twin scenes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PLC data tags are manually connected to 3D digital twin models through coding, then the connection accuracy is improved, but the development time and complexity increase significantly
Solution Approach 1:
The system enables automatic self-connection of PLC data tags to 3D digital twin models through AI-based image recognition. The server automatically identifies objects in images, matches them with digital twin models, and connects corresponding PLC data tags without requiring manual coding intervention, thus achieving both high accuracy and reduced development time
Solution Approach 2:
The patent replaces the manual coding mechanism with an AI-based automated mechanism. Instead of requiring programmers to write code to connect PLC tags to 3D models, the system uses image recognition technology to automatically identify objects and establish connections, substituting mechanical coding work with intelligent automation
2Reliability
If manual coding is used to connect PLC data tags to 3D models, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the complex coding logic from the system and replaces it with AI-based image recognition. By taking out the manual programming requirement and substituting it with automated object recognition and matching, the system maintains connection reliability while significantly reducing the complexity of the implementation process
Solution Approach 2:
The system introduces an AI-based image recognition server as an intermediary between PLC data tags and 3D digital twin models. This intermediary automatically performs object identification, model matching, and tag connection, simplifying the overall system architecture while ensuring reliable connections through intelligent processing
3Ease of operation
If AI-based image analysis is used to automatically connect PLC data tags to 3D digital twin models, then the ease of operation is improved, but the measurement precision challenge arises
Solution Approach 1:
The patent replaces manual object identification and tag connection processes with AI-based image recognition technology. The server automatically detects objects in images, identifies their characteristics, matches them with corresponding 3D digital twin models, and connects PLC data tags, making the system easy to operate while maintaining high recognition accuracy through advanced AI algorithms
Data Source
AI summary
A supervisory control and data acquisition (SCADA) system to which a digital twin using image analysis based on artificial intelligence (AI) is applied and a control method thereof, which performs AI-based image analysis on image information to recognize an object included in the corresponding image information, confirms a specific three-dimensional (3D) digital twin model related to the previously recognized object among a plurality of pre-stored 3D digital twin models, searches for a specific programmable logic controller (PLC) data tag related to the previously confirmed specific 3D digital twin model from a plurality of pre-stored PLC data tags, connects the searched specific PLC data tag to the corresponding specific 3D digital twin model, and applies the PLC data tag collected from a PLC in real time to the corresponding specific 3D digital twin model and displays the specific 3D digital twin model as a SCADA scene.