Virtual Field Device Expansion for Automation Load Management
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Solution Overview
Problem
Existing automation systems face challenges in expanding production capabilities without disrupting ongoing processes, as the integration of new field devices often leads to system standstills due to insufficient power reserves and communication limitations, resulting in potential production stops and financial losses.
Innovation Solution
A method that allows for a safe and scalable 'stress test' by using virtual field devices to emulate real ones, enabling gradual load assessment and expansion, thereby avoiding production halts by ensuring that communication and control loads do not exceed predefined limits before integrating real field devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If new field devices are integrated into the automation device, then production capabilities are expanded, but system standstills occur due to insufficient power reserves and communication limitations
Solution Approach 1:
The patent applies preliminary action by configuring virtual field devices before integrating real field devices. The virtual devices are used to test communication loads and power reserves in advance, allowing the system to prepare for expansion without disrupting ongoing production. This pre-testing phase identifies potential bottlenecks before they affect actual production operations.
Solution Approach 2:
The patent uses virtual field devices as intermediaries between the automation device and real field devices. These virtual devices simulate the communication and power requirements of real devices, acting as a buffer that allows safe testing and configuration without directly impacting production systems. The virtual devices mediate the integration process by providing a risk-free environment for load assessment.
2Productivity
If real field devices are integrated directly, then expansion is achieved quickly, but production stops occur due to insufficient load reserves
Solution Approach 1:
The patent performs preliminary configuration and load testing using virtual field devices before integrating real devices. This advance preparation ensures that when real devices are integrated, the system is already optimized and ready to handle the additional load, preventing production stops and enabling seamless expansion without time loss.
Solution Approach 2:
The patent creates virtual copies of real field devices to simulate their behavior and resource requirements. These copies allow the system to test integration scenarios, communication protocols, and power consumption patterns without using actual production equipment. The virtual copies replicate the resource demands of real devices, providing accurate predictions of system behavior under expanded conditions.
3Reliability
If virtual field devices are used for stress testing, then production disruptions are avoided, but configuration complexity increases
Solution Approach 1:
The patent implements virtual field devices with multi-functionality, serving as both simulation tools for stress testing and as functional proxies for real devices during configuration. The same virtual device infrastructure used for testing can also validate communication protocols and control logic, reducing the need for separate testing and configuration processes. This universal approach consolidates multiple tasks into a single framework.
Solution Approach 2:
The virtual field devices are configured to automatically monitor and report communication loads, power consumption, and system performance metrics. This self-monitoring capability reduces the manual effort required for stress testing and configuration validation. The virtual devices autonomously generate test data and provide feedback on system capacity, minimizing the need for complex manual configuration procedures.
Data Source
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AI summary
The invention relates to a method for extending an automation device (1) with at least one field device (9). First, a virtual field device (5v) and a control module (10s) are virtually connected to the automation device (1), and the communication and control load caused by this virtual field device (5v) and control module (10s) is determined. If the determined communication and control load does not exceed a predefined load limit, the control module (10s) is enabled by the user and integrated into the control program (10), and the corresponding real field device (9r) can be connected to the bus (8).