Virtual Field Device Startup Using FDI Simulation Models
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Solution Overview
Problem
The startup phase of industrial automation networks is characterized by high time and cost pressure, with existing methods requiring significant manual effort and posing risks due to the complexity of field devices and the need for real-time validation, which can lead to errors and safety hazards, especially in hazardous environments like ammonia production.
Innovation Solution
A method that extends the user interface plug-in of the FDI package with a simulation model for field device behavior, allowing for a virtual startup by providing a high-quality simulation model created by the manufacturer, which is platform-independent and can be accessed through a software tool, enabling simulation patterns and co-simulation coupling for more comprehensive process models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual configuration and parameterization methods are used during startup, then flexibility and adaptability are maintained, but time consumption and error risks increase significantly
Solution Approach 1:
The patent uses virtual copies (simulation models) of field devices to replicate their behavior during startup. These virtual devices mirror the properties, parameters, and behaviors of real field devices, allowing configuration and validation to be performed on copies before deploying to actual devices. This eliminates errors in manual configuration while maintaining the ability to adapt to different real devices.
Solution Approach 2:
The patent performs configuration, parameterization, and validation actions in advance during the startup phase using simulation models. All necessary setup work is completed beforehand in the virtual environment, so that when real field devices are deployed, they are already pre-configured and validated, significantly reducing on-site commissioning time and eliminating runtime errors.
2Reliability
If comprehensive simulation models are created to validate field device functionality, then error risks are reduced, but model creation complexity and resource requirements increase
Solution Approach 1:
The patent creates universal simulation models that can represent multiple types of field devices with a single unified model structure. The simulation model engine can instantiate different virtual field devices from the same model template by configuring appropriate parameters, eliminating the need to create separate complex models for each device type while maintaining comprehensive validation capabilities.
Solution Approach 2:
Instead of creating entirely new complex simulation models, the patent uses simplified virtual copies that replicate only the essential behaviors and parameters needed for validation. These virtual field devices contain only the critical properties and functions necessary for startup validation, reducing model complexity while maintaining sufficient accuracy for error detection.
3Loss of time
If virtual startup with simulation models is implemented, then startup time is reduced and errors are minimized, but the initial setup effort and software tool requirements increase
Solution Approach 1:
The simulation model engine automatically performs validation, error detection, and configuration verification without requiring manual intervention. The system self-validates the virtual field device configurations against predefined criteria and automatically generates validation reports, reducing the need for manual setup effort while achieving comprehensive validation.
Solution Approach 2:
The patent introduces a software tool as an intermediary between the engineer and the field devices. This tool provides pre-built simulation model templates, automated validation rules, and configuration assistance, reducing the initial setup effort by handling complex model creation and validation logic automatically while still enabling virtual startup for time savings.
Data Source
AI summary
A field device and method for starting up an industrial automation network, wherein to allow virtual start-up of at least one field device, an field device integration package is provided, whose user interface plug-in has an extension that allows a software tool to access a simulation model for the behavior of the at least one field device, and upon virtual start-up, the simulation model is used to reproduce the response of the field device, where a process model or interfacing of an external process model via a co-simulation coupling can also be used to stimulate the reproduced field device behavior, and where because the models with the FDI package are provided by the field device manufacturer, correct simulation and hence minimization of the risks upon start-up of industrial installations can be expected.