Virtual Module Simulation for Modular Process Commissioning
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Solution Overview
Problem
Virtual commissioning of modular process installations is challenging due to the lack of simulation models and emulations for automation engineering, especially when modules come from different manufacturers, leading to increased effort or impossibility in simulation and testing.
Innovation Solution
A method for generating a virtual module for each real module, comprising a controller and module-specific simulation models, which replicates the module's process and is designed to facilitate computer-aided simulation, allowing for virtual commissioning and testing independently of specific simulation software.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If virtual commissioning is performed for modular process installations, then testing and validation can be conducted before real commissioning, but simulation models and emulations are not present or based on different software leading to increased effort or impossibility
Solution Approach 1:
The system segments the modular process installation into individual process units, each with its own controller and simulation model. This segmentation allows each unit to be independently modeled and simulated, then integrated into the overall system simulation, reducing the complexity of creating a monolithic simulation model.
Solution Approach 2:
The patent creates virtual copies of the actual process units through simulation models that replicate the behavior of physical equipment. These virtual models include controllers that emulate the actual control systems, enabling virtual commissioning without requiring physical hardware, thus eliminating the need for different software platforms and reducing integration complexity.
2Adaptability or versatility
If modules from different manufacturers are integrated, then system versatility and functionality are improved, but automation engineering is known to only one manufacturer making simulation impossible
Solution Approach 1:
The patent implements a universal simulation framework that can accommodate process units from different manufacturers. The system uses standardized interfaces and communication protocols that allow virtual models to represent diverse equipment types, enabling simulation of heterogeneous systems without requiring manufacturer-specific simulation software.
Solution Approach 2:
The simulation models use parameterized representations of process units where manufacturer-specific details are captured as configurable parameters. This allows the same simulation framework to adapt to different manufacturers' equipment by adjusting parameters rather than requiring completely different simulation models, thereby simplifying the integration of multi-manufacturer modules.
3Productivity
If virtual commissioning is performed without standardized data containers, then simulation can proceed, but large amounts of effort are required and standardization is lost
Solution Approach 1:
The patent introduces standardized data containers that provide a uniform structure for representing process units, controllers, and simulation models regardless of the actual equipment manufacturer or type. This homogenization of data representation enables automated generation of simulation models and reduces the effort required for virtual commissioning while maintaining standardization across different systems.
Data Source
AI summary
A method and a device for the computer-assisted simulation of a modular technical system, wherein for each real module of the modular technical system, a corresponding virtual module is generated, is provided. The virtual module includes a controller for controlling a module-specific process and at least one module-specific simulation model, to which model type information is assigned, for simulating the model-specific process. The virtual module is designed to simulate the module-specific process that is controlled by the controller by means of the module-specific simulation model and/or the controller of the real module, and is provided for a computer-assisted simulation of the modular technical system as a data container. In particular, the following allows a virtual start-up of modular process systems.