EP1374037A2

EP1374037A2 - Method and device for automatically generating simulation programs

Info

Publication number: EP1374037A2
Application number: EP02724115A
Authority: EP
Inventors: Lueder Heidemann; Hansjürgen SEYBOLD
Original assignee: Siemens AG
Current assignee: Siemens AG
Priority date: 2001-03-29
Filing date: 2002-03-20
Publication date: 2004-01-02
Also published as: WO2002079974A3; WO2002079974A2; US20040059553A1

Abstract

In order to automatically generate simulation programs, basic program operations of a real program are made available in the recipe management. Furthermore, process parameters of the real process are made available in the sequence logic (SFC). The basic program operations are automatically linked to the process parameters in order to simulate the method, whereby a simulation model is generated that is initialized according to the real process. Method simulation is advantageously controlled simultaneously by the process control system of the real process. Parallel running of the real process with the simulation process enables effective monitoring and improved maintenance management.

Description

description

Method and device for the automatic creation of simulation programs

The present invention relates to a device and a method for creating simulation programs according to the preamble of claim 1 and in particular for the maintenance of systems.

Required maintenance measures are usually performed event-triggered or time-triggered. In the case of event-controlled maintenance measures, a process component is exchanged or repaired if it has failed. In contrast, maintenance measures are carried out at regular intervals in the case of time-triggered maintenance measures, which is to prevent the process system from failing.

Preventive maintenance is particularly important for very complex systems. The failure of a production plant, for example, can result in very high costs. For this reason, complex systems are often monitored by sensors and the measured values are used to identify maintenance needs. Typically, measured values of system components are recorded and recorded during the process. From the changes in the measured values, trends can be identified that may require maintenance measures. For example, the pressure in a system can increase over time, which indicates, for example, a blockage in a pipeline. In addition, vibrations can give an indication of bearing wear or the measurement of the phase angle triangle in a drive can indicate an unfavorable slip. However, the individual components of every system cannot be constantly monitored for wear and the like. For example, monitoring at very high process temperatures ratures, very compact plant design or excessive complexity of individual components.

Process simulation programs are used for the engineering and testing of plants and processes. Such simulation programs are created by specialists and adapted to individual needs. Accordingly, it is very complex to create simulation programs for large systems or complex processes.

The object of the present invention is therefore to simplify the creation of simulation programs, particularly with regard to maintenance measures.

According to the invention, this object is achieved by a method for creating a simulation program by providing basic program operations and providing process parameters of a real process, and automatically linking the basic program operations to the process parameters for initializing the simulation program.

Furthermore, the above-mentioned object is achieved by a device for simulating a system with a storage device for providing basic program operations and a control device for simulating a real process on the basis of the basic program operations, and a reading device for reading in process parameters of the real process, the basic program operations being carried out by the control device for a simulation process can be automatically linked to the process parameters for initializing the simulation process.

Advantageously, the simulation model or program can be derived automatically from the real process by the invention. Therefore, no additional engineering effort is required if the control of the real system is already in place. This increases the acceptance of users, Si u lations models especially for maintenance.

Further advantageous developments of the device according to the invention and the method according to the invention can be found in the subclaims.

The present invention will now be explained in more detail with reference to the accompanying drawings, in which:

1 shows a data flow diagram of a real process and a parallel simulation process according to the invention;

2 shows a signal flow diagram for alarming and predicting maintenance requirements; and

Fig. 3 is a signal flow plan for performing maintenance measures.

The exemplary embodiments described below show preferred embodiments of the present invention.

1 shows a schematic signal flow diagram of a control of a real process in the left half of the image and a parallel simulation process in the right half of the image. The order control or a so-called scheduler serves as the starting point for controlling the real process. A recipe control (batch flexible) is controlled with the order data. The recipe control system obtains the desired recipe (s) from a database, the recipe management. This control is suitable for batch processing processes as well as for continuous processes.

The actual system control or automation takes place in the block labeled “Sequence Logic ¹ ” in FIG > ω t-ro P ^{1 1}

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A corresponding simulation process is shown in the right-hand side of the image in FIG. 1. Like the real process system, the simulation system consists of a coordination module with the following sequence logic and equipment function modules. The input / output periphery of the real process is simulated by a logical periphery. The real process itself has to be simulated both in its components and in the process itself. The components are simulated in a so-called equipment simulation and the process simulation takes place by suitable interconnection of the equipment simulation modules.

The logical periphery and the equipment simulation can be automatically generated by a semantic manager from a library with RB classes (reaction modules).

Equipment master data, substance master data, pipeline master data etc. are included in the process simulation. Equipment master data are, for example, the diameter of containers, performance characteristics of valves, pumps, etc. Material master data are quantities, grain size, etc. of the substance used. Finally, the pipe master data reflect the dimensions and other relevant sizes of the pipes used. All master data can be stored in libraries.

The real process is now synchronized with the simulation process. This means that both processes run in parallel, so that a direct comparison of the process results is made possible. It doesn't have to be the entire real one

Process can be simulated, for example, a particularly critical process step, which for example requires constant monitoring, can be simulated.

The simulation enables the entire system and / or essential system components to be simulated as a virtual system. Through the targeted replication of system parts and the o ω t MP ^*

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" ^* : p- Ph 0 P- Cn φ Φ • q tr O 0 cn φ 0 0 Φ • P φ p- φ φ et Hi rt Φ Ph

Φ • P • P 0: cn H P- tr et cn 0 0 r H 0 P- Φ cn 0: 0 Ω tτ cn rt P- 0 rt Φ 0 cn s:

PS φ PS PP [- ^■ 0: P- P- <q Φ 0 cn cn 0 P "H Φ Φ 0 tr 0 P- ¹ 0 cn P <! Φ cn h- ^* cn Qa Ω <! Φ 0 Hi et Ω cn Φ cn <τ) O 0 PS H 0 P- ¹ 0

0 φ O Q. Φ P 0 rt rt 0 tr Φ -P Φ 0 ^* - O tr Φ cn rt H Φ tsi. P- φ • q rt Z α

PS PS 0 P- cn 0 tr Φ ^• «tr PS 0 HH 3 Φ TS P- O p- Φ P cn 0 • P- ιq P- Φ P -XJ φ H Φ 0 Ph cn 0 0 0 3 • PNP cn α Φ p- cn 0 PS Hi

0 cn PPH rf P P- 0 0: cn 0 P rt Üx ^* H P- Φ φ Φ cn cn Φ n 0 α 0:

P Ω Φ PJ Φ: OS α Φ cn -P rt £) 0 P- p 0 rf ti ω -u cn PS P- Qa 0 H v tr ^ 0 PS 3 tr P. O Φ 3 0 rt ^* Φ cn cn ιq rt ^• q cn φ 0 to Φ 3 NP o φ C Hl Hi 0 ^• X) cn Qa Ω Φ φ S φ XH cn Φ 0 0 Qa 0 0 P 1 Hl P ιq PS Pr Hi P- πd cn 0 tr Φ 0 0 'P- cn Φ cn 0 0 p- 0 φ cn 0

O 0: 0 Φ rt Φ P 0 H Φ • P cn 0 Φ Φ cn rt P- ^ 3 3 P 0 Pi s: cn

3 0 PS ρ SP P- P P- H 0 P- Φ rt cn rt Φ cn Φ rt Φ 0 ^• p Φ rt Φ to

P et 0 P- O Φ Φ s Φ 3 cn 0 ϊö O Φ Φ 0 φ PS Φ rt H cn P-. > t P- CΛ

^• X) P- P- Qa φ 0 PS 3 3 Φ Ό φ Φ 3 M Pi 0 Φ ^• P Φ 0 OO 0 P 3 P-

Pi P- o Φ cn cn cn rf φ r P- Pi 0 0 0 0 Φ Pi <1 P- ^• p H rt N cn 0 Ph Φ 0 3

0 P. Φ 0 φ H rt rf -XI Φ Φ P- P- ¹ rt iP 0 S rt 0 tr tr 0 p- Φ P- rt 0 H 0

N P- 0 0 Φ O φ 0 PS cn ^• P P- P- ^• q 0. 0 rt ^• O cn φ TJ φ 3 0 H 0 P- ¹

Φ tr IH 0 H PS rt cn Ω H cn 0 0. cn 0 cn 0 0 0 Q rt 0 ω PS PS P ^* cn Φ Hi 0 0 pj Z tr O Ω Φ 0 <qt? 3 P p- Φ cn Φ P- ¹ rt ^• q H P- rt cn cn O Hl 0 ^* P 3 Qa 5 3 P- Φ φ tsi p Φ 0 cn Φ ω ω ^* P cn 0 O cn 0 O P-

H "P- & o 0 et rt φ φ ^* P P- cn Φ φ H <PS Ω PS rt 3 cn 0 0 0

Φ 3 0 H Hl N Φ PPP et Φ cn cn P- POP ^ ¹ tr to O <p- 0 rt Qa cn 0 p- 0 i P Φ P • q φ P- φ (- ^■ φ cn cn M 0 φ PS 0> Φ φ • q OO rt Φ O 3 cn rf P ^* et φ 0! Φ 3 rt ι-1 0 P- φ 0> P 0 -q 0 0 0 H 0 0 P- 0 ^• PO 3 cn 0 P- H Qa O tr 0: 3 cn ^ P Φ 0 Ph 0 P- ¹ 0 cn cn Φ Φ PO rt O \ - ~ φ 0 Φ ^• XJ - N tr 0 P- tr H cn 1 P Pi g P ^* P Ω H Pi Φ P cn P- 0 P- 0 1 Φ 0 0 φ P ¹ 0 1 φ Φ φ 0 P PS p Φ PS tr 0 0 P- ¹ Φ

1 o 1 1 1 1 Pi 0 0 1 0 1 1 o PS O 0 1 P- ¹

0 1 1 1 1 1 ^• PP "

no additional engineering effort is required for parallel simulation.

The principle of the simulation models is created automatically from the recipes of the real process. In general, the simulation models from semantic programs, semantic peripheral assignments and / or process engineering engineering documents, i. H. the information that the virtual system needs to describe its components and how they work together. For automatic operation, this information is converted into the parameterization and interconnection of the virtual system.

As already mentioned, a meaningful comparison between real and simulated process steps requires precise synchronization. An exact starting point must also be defined, which is done by the initialization. As indicated by a dashed line in FIG. 1, the initialization of the simulation process can be controlled online by the logic sequence of the original system. In this way it can be ensured, for example, that a container in the original system and in the simulation in a specific process step of a specific recipe each have a defined fill level.

The single arrows in FIG. 1 mean signaling links or action links and the double arrows mean data links which are required, for example, for parameterization and engineering.

FIG. 2 shows a schematic signal flow plan for obtaining a maintenance request based on the diagnosis that resulted from the comparison between the real process and the parallel simulation process. Explanations of the blocks can be found in the table at the end of the description. 3 shows a signal flow diagram which shows the further processing of a maintenance request in a maintenance management. Accordingly, service measures are carried out if this is necessary due to information procurement, material / resource procurement, maintenance planning and the maintenance request. The material / resource management and the budget affect the maintenance planning. In addition, the system model is used to obtain information.

table

(Stirring, heating, filling, etc.). Each individual model has parameters (substance, unit and product parameters). The simulation runs under BF control (BF gives the step start to SIMIT with the parameter set valid for the step and the end criterion (e.g. end temperature 92 ° C). SIMIT starts simulation and, after reaching the end criterion, gives the for GO defined result parameter set to Diag.

SIMIT does not (yet) master material conversions, such operations (eg "reaction", "synthesis") must be simulated using simple empirical equations if several GOs are to be run through in a "simulation chain".

Because this process is under the control of BF, no project-specific engineering work is required. SIMIT "only" needs process- / project-neutral models.

Equipment behavior Technological monitoring of equipment behavior SIMIT has models of (technological) equipment behavior (e.g. resistance heating element with time behavior, heat transfer, heat flow in the fabric, etc.). Otherwise analogous as above

Arch archive plant history of the product and

Claims

claims

1. Method for creating a simulation program by providing basic program operations and providing process parameters of a real process,

marked by

automatic linking of the basic program operations with the process parameters for initializing the simulation program.

2. The method according to claim 1, wherein the automatic linking is carried out by a process control system that controls or regulates the real process.

3. The method according to claim 1 or 2, wherein the process parameters are provided by providing predefined data packets.

4. The method according to claim 3, wherein the data packets are parameter triples, in particular a parameter for a substance type, a container type and a substance quantity.

5. The method according to any one of claims 1 to 4, wherein the

Process parameters can be obtained from a production recipe of the real process.

6. The method according to any one of claims 1 to 5, wherein the basic program operations are combined on the basis of one or more semantic programs, semantic peripheral assignments and / or procedural engineering documents for controlling the real process to form the simulation program.

7. A method for simulating a real process with the method sections according to one of claims 1 to 5 and Another step of controlling the simulation process through a process control system of the real process.

8. Procedure for maintaining a system

Executing a real process in the system,

Execution of a simulation process according to claim 7 in time parallel to the real process, the simulation process simulating at least part of the real process,

Comparing the simulation process with the real process or part thereof to obtain a comparison result and

Deriving maintenance measures from the comparison result.

9. Device for simulating a system with

a memory device for providing basic program operations for a simulation process and

a control device for simulating a real process on the basis of the basic program operations,

marked by

a reading device for reading in process parameters of the real process, the basic program operations being automatically connectable to the process parameters for initializing the simulation process by the control device,

10. The device according to claim 9, wherein the control device is integrated in a process control system that controls or regulates the real process.

11. The device according to claim 9 or 10, wherein the process parameters are predefined data packets.

12. The device according to claim 11, wherein the data packets are parameter triples, in particular a parameter for a substance type, a container type and a substance quantity.

13. Device according to one of claims 9 to 12, wherein the process parameters can be read by the reading device from a production recipe storage unit of the real process.

14. Device according to one of claims 9 to 13, wherein one or more semantic programs, semantic peripheral assignments and / or procedural engineering documents of the real process can be read in by the reading device and can be used by the control device to combine the basic program operations.

15. Device for the maintenance of a system in which a real process can be carried out, with a simulation device according to one of claims 9 to 14 for simulating at least a part of the real process by the simulation process, the simulation process being able to be carried out in parallel with the real process.