Concurrent Simulator Adaptation for Real-Time Machine Control
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Solution Overview
Problem
Complex machines require flexible and accurate real-time simulation for efficient monitoring and control, but existing methods demand high complexity and computing resources, often necessitating manual interventions and interruptions during operation.
Innovation Solution
A method and assembly that continuously record and analyze operating signals to detect differences between simulated and measured states, using predefined difference types and associated simulator variants to adapt the simulation in real-time, reducing the need for manual interventions and optimizing resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a detailed and flexible simulator is used to accurately replicate machine responses to various changes, then the accuracy and adaptability of machine monitoring improves, but the computing resources and complexity required increase significantly
Solution Approach 1:
The patent segments the simulator into a modular architecture consisting of a base simulator and multiple simulator variants, each specialized for specific difference types. This allows the system to activate only the necessary variant when a particular type of change is detected, rather than maintaining a single comprehensive complex simulator for all possible scenarios.
Solution Approach 2:
The system dynamically adapts the simulator configuration based on detected difference types. When a specific difference type is identified through pattern recognition, the corresponding simulator variant is activated or loaded, allowing the system to adjust its complexity level dynamically rather than maintaining maximum complexity continuously.
2Measurement precision
If a detailed and flexible simulator is used to accurately replicate machine responses, then the measurement precision of operating data improves, but the computing resources required increase
Solution Approach 1:
Instead of using a fully detailed simulator for all operating conditions, the system applies partial simulation by selecting and activating only the specific simulator variant needed for the currently detected difference type. This partial action approach maintains measurement precision for the relevant parameters while consuming fewer computing resources than a complete simulator would require.
3Adaptability or versatility
If manual interventions are implemented to adjust the simulator during machine changes, then the simulator can be adapted to new conditions, but productivity decreases due to interruptions
Solution Approach 1:
The system implements self-service automation where the automated difference detection mechanism identifies machine changes and automatically selects and activates the appropriate simulator variant without requiring manual intervention. This allows the simulator to adapt to new conditions autonomously, maintaining both adaptability and continuous machine operation without productivity interruptions.
Solution Approach 2:
The system continuously compares actual machine operating data with simulated data to detect differences, creating a feedback loop that automatically triggers simulator variant selection. This closed-loop feedback mechanism ensures the simulator remains adapted to current machine conditions while operating continuously without manual interruptions.
Data Source
AI summary
To monitor or control a machine, current operating signals are captured continuously, and a current operating state is measured continuously. On the basis of the captured operating, a simulated operating state is determined continuously by a concurrent simulator. In addition, upon detection of a difference between the simulated operating state and the measured operating state, a difference pattern that quantifies the deviation or a change in the measured operating state is compared with a plurality of specified difference types which are characteristic of a modification of the machine or a machine operation, and each of the difference types is assigned a difference-type-specific simulator variant. Depending on the result of the comparison, one of the difference types is then selected. On the basis of the simulator variant assigned to the selected deviation type, the concurrent simulator is adapted, and the machine is monitored or controlled using the adapted concurrent simulator.