EP2156425A1

EP2156425A1 - Training system for an automated system for controlling a technical process

Info

Publication number: EP2156425A1
Application number: EP08760209A
Authority: EP
Inventors: Roland Stein
Original assignee: Siemens AG
Current assignee: Siemens AG
Priority date: 2007-06-05
Filing date: 2008-05-29
Publication date: 2010-02-24
Also published as: KR101168486B1; KR20100018532A; DE102007026502A1; WO2008148696A1

Abstract

The invention relates to a training system (1) for an automated system for controlling a technical process, in particular an automated system on a ship. Said system comprises a process simulator (2) for simulating the technical process and for generating process data (P) in accordance with control data (S) and a control simulator (3) for generating control data (S) for the process simulator (2) and output data (A) for one or more output components (5) of the training system (1) by the simulation of the control devices of the automated system in accordance with the process data (P) and the input data (E) from input components (6) of the training system (1). According to the invention, the system is provided with a recording and importing unit (8) for recording the output data (A), input data (E), internal control condition data (SZ) of the control simulator (3) and internal process condition data (PZ) of the process simulator (3) and for importing the recorded output data (A) into the output components (5), importing the input data (E) and the internal control condition data (SZ) into the control simulator (3) and importing the internal process condition data (PZ) into the process simulator (2).

Description

description

Training system for an automation system for controlling a technical process

The invention relates to a training system for an automation system for controlling a technical process, in particular a ship automation system, comprising a process simulator for simulating the technical process and for generating process data as a function of control data and a control simulator for generating the control data for the process simulator and of output data for one or more output components of the training system by simulation of the controllers of the automation system in dependence on the process data and input data of input components of the training system.

The essential task of such a training system is to train operating personnel (users / users) with regard to the operating sequences in the automation system. For example, such training systems are used for the training of ship personnel at the central automation system of a ship. The central ship automation system is used to control, monitor and diagnose the various facilities on board a ship. It should enable a safe operation of the ship and ensure its operational readiness.

Such ship automation systems are becoming more and more complex, especially with underwater vessels. For this reason, a good training of the ship's personnel is becoming more and more important. Targeted training can ensure that an operator aboard the ship will make the right decision, even in emergency situations. Through a At the beginning of the training system explained, specific scenarios can be repeatedly simulated and trained without the need for the actual automation system. A training system for a submarine automation system is known, for example, from DE 10 2004 040 496 A1.

The training can take place either aboard the ship (it is a so-called "on-board training system") or on land (as a so-called "land based training system").

Such a training system has the requirement to be able to analyze a training situation more accurately during a training at a predeterminable time by a "snapshot", ie a snapshot of the simulation data present at that time, including the output data displayed on the output components, and the training to be able to continue at a predeterminable later time without much loss of time and information at the time of the snapshot.

It is an object of the present invention to provide a training system which meets the aforementioned requirement. The solution to this problem is achieved by a training system according to claim 1. Advantageous embodiments are the subject of the dependent claims.

By recording the internal state data of the control simulator and the process simulator, both a state image of the control simulator and a

State image of the process simulator shortly before and / or at the time of the snapshot (ie the snapshot) are held. On the other hand, by recording the data from the control simulator to the output components and from the Input components to the control simulator an image of the traffic at the interface between control simulator and visualization are recorded just before and / or at the time of the snapshot. The important thing here is that not only the HMI displayed on the output components

Images, e.g. by means of a video recorder, but that the data traffic between the control simulator and the visualization is recorded directly.

By importing the recorded data into the output components, the control and the process simulator, the training session can be continued at a predeterminable later time without loss of time and information at the time of the snapshot, because by recording the recorded data, the training system is in the same state as brought in at the time of the snapshot.

According to an advantageous embodiment of the invention, the recording and Einspieleinrichtung at least one recording and input unit for the data recording and - recording and a control unit for controlling the data recording and recording, i. activation and deactivation of data recording and recording.

For controlling the data recording and recording by a teacher system, the control unit can be coupled with advantage by the teacher system.

Advantageously, the control devices in the control simulator are simulated by a software emulation. This allows implementation of the control simulator on standard computer hardware, often referred to in the literature as COTS (= Commercial of the Shelf) hardware. Preferably, the teacher system for changing values of internal process state data of the process simulator, bypassing the recording and input device directly coupled to the process simulator.

In this case, a local on-site operating device can be integrated into the training system in that it can be coupled to the process simulator.

Alternatively, an on-premises local operator can be incorporated into the training system by being replicated in the process simulator.

Another possibility for integrating a local on-site operating device is that it is modeled as a graphical user interface on a separate computer of the training system.

The invention and further advantageous embodiments of the invention according to features of the subclaims are explained in more detail below with reference to embodiments in the drawing. It shows:

1 shows a basic structure of a training system,

FIG. 2 shows an example of a possible hardware system configuration for the training system of FIG. 1, FIG. 3 shows an integration of a decentralized operating device through

FIG. 4 shows an integration of a decentralized operating device by a simulation in the process simulator, FIG.

5 shows an integration of a decentralized operating device by a replica in a separate computer. A training system 1 shown in FIG. 1, for example for a ship automation system, comprises a process simulator 2, a control simulator 3, a visualization 4 as an HMI interface (HMI) with output and input components 5 and 6, a teacher system 7 and a recording and Einspieleinrichtung 8.

The process simulator 2 simulates the technical process. In the case of a ship, the technical process in a simplified form can be described "valves, pumps and motors," simple binary and analog process signals and peripheral subsystems such as "E-conditioning and fire alarm system" for example by Simu ^¬ lation of drive components such.

Functionally, the process simulator 2 can therefore represent at ^¬ play in three levels: a) The process signal level forms all process signals (actuator / sensor signals) in the simulator from that between the control-simulator and the real process on the process images "inputs" and "outputs " be replaced. b) The level of the component simulation simulates the behavior of the electric drives of motors, valves etc. with corresponding model components. The commands and feedback of the drives come from the process ^{signal ¬} level. This part of the process simulation is system-specific and involves the reproduction of the automation components ^¬ binary value and analog processing, valves and motors. In the component simulation, no physical process is simulated, but only the drive components coupled via the "process input image" as well as simple binary and analogue signals. c) The level of technological simulation simulates the physical behavior of the process. The control devices (PLCs) of the automation system, eg controllers of the type "SIMATIC S7-300 / 400" by the applicant, are simulated by the control simulator 3. This is done with SoftPLC instances 9 (embedded systems) which are connected to one or more computers of the Training system 1. The SoftPLC instances 9 execute the original programs of the automation devices, for example the original software of the "SIMATIC S7-300 / 400" controllers of the automation system. Every instance 9 has one

Interface to the visualization 4 and to the process simulator 2.

The visualization 4 communicates via a communication interface 10, preferably in the form of a common

Memory usage ("shared memory") with the instances 9 of the control simulator 3.

In this case, the process simulator 2 communicates with the instances 9 of the control simulator 3 via a communication interface 11, preferably also in the form of a shared memory usage ("shared memory").

The visualization 4 with the output and input components 5 and 6 can be the actual operating stations of the system, e.g. Operating stations in the ship's technical control station, or to act replicas thereof on computerized student workstations of the training system 1.

The process simulator 2 generates a process image in the form of process data P, which are transferred to the instances 9 of the control simulator 3. The instances 9 of the control simulator 3 in turn generate for the control of the process as a function of these process data P and of input data E, which are passed to them from the visualization 4, control data S, which are passed to the process simulator 2. The simulated process is controlled in dependence on this control data S.

In addition to the control data S, the instances 9 of the control simulator 3 also generate output data A, which are transferred to the output components 5 of the visualization 4 and displayed on these output components 5 in the form of an image. Of the operating components 6 of the visualization 4, in turn, if necessary in response to displayed output data A, are read by a user, e.g. a student, entered input data E and passed to the instances 9 of the control simulator 3.

The simulated process itself is defined in the process simulator 2 by internal process state data PZ. These may be, for example, values of state parameters or of timers or actuators (e.g., a valve position when opening a valve). Overall, the state data PZ represent an exact replica of the process model level.

The signal level reproduced by the instances 9 of the control simulator 3 is defined by internal control state data SZ of the instances 9. Overall, the control state data SZ reproduce an exact image of the signal level.

The teacher system 7 serves to control the training sequences and the analysis of the training results by a teacher.

In order to be able to understand and analyze an exercise, a so-called "snapshot", ie a snapshot, which is available at this time the simulation data including the output data displayed on the visualization can be recorded and a training can be continued at a later time at the time of the snapshot.

For the generation of the "snapshots", the recording and input device 8 records the output data A, the input data E and the internal state data of the control simulator and the process simulator SZ or PZ together with a time stamp and stores them.

These data can now be transferred to the teacher system 7 and analyzed there. If the training session is to be continued at the time of the snapshot, the recording and input device 8 plays the recorded output data A into the output components 5, the inputted input data E and internal state data of the control simulator SZ into the control simulator 3 and the internal state data of the process simulator PZ in FIG the process simulator 2 a.

By importing the recorded data into the output components 5, the control simulator 3 and the process simulator 2, the training session can be continued at the time of the snapshot without any loss of time and information exactly at the time of interruption. By importing the recorded data, the process simulator 2, the control simulator 3 and the output and input components 5 and 6 are brought into the same state as at the time of the snapshot.

The recording and input device 8 can in this case be designed such that the recording of the output data A and the input data E at a higher frequency than the recording the internal control state data SZ and the internal process state data PZ takes place. For example, the recording of the output data A and the input data E every one second and the recording of the internal control state data SZ and the internal process state data PZ are performed only every 5 seconds. Although this leads to low delays in continuing the training session at the time of the snapshot, but the data volume to be stored is much lower, since the extent of the stored output data A and input data E is much lower than the extent of the stored internal control state data SZ and internal process state data PZ.

For recording and later loading the output data A and the input data E, the recording and input device 8 has access to the communication interface 10 between the control simulator 3 and the visualization 4.

The recording and later loading of the internal process state data SZ, PZ takes place via a communication interface 12, preferably designed as a remote interface, between the recording and input device 8 and the process simulator 2.

Recording and later loading of the internal control state data SZ into the control simulator 3 takes place via the process simulator 2 and thus via the communication interface 11 between the control simulator 3 and the process simulator 2 and the interface 12 between the recording and input device 8 and the process simulator 2.

In detail, the recording and input device 8, a control unit 13 for controlling the data recording and recording, a first recording and input unit 14 for receiving the output data A and the input data E and a second recording and input unit 15 for receiving the internal control state data SZ and the internal process status data PZ, wherein the control unit 13 communicates with the recording - And Einspieleinheiten 14, 15 is connected. The control unit 13 and the second recording and input unit 15 may in this case also be combined into a single unit 16.

The control unit 13 communicates with the teacher system 7 via a communication interface 17, preferably a UDP interface by means of UDP telegrams. The control of the process simulator 2 and the recording and recording functions by the teacher system 7 via this interface 17. The commands of the teacher system 7 are evaluated in the control unit 13 and implemented accordingly. The control unit 13 controls for this purpose the areas of the process simulator 2, which are necessary for the implementation of the commands. Feedback received by the process simulator 2 on the execution of the commands passes the control unit 13 to the teacher system 7 on.

Thus, a teacher can be given a command "Snapshot Capture" to the control unit 13 via the teacher system 17, whereupon this initiates taking a snapshot After analyzing the recorded data, the teacher can use the teacher system 7 to issue a command "Resume the training for the snapshot." Time of the snapshot "to the control unit 13, whereupon this by starting the recorded data in the various components of the training system initiates the continuation of the training. The following additional functionalities of a teacher system can be executed by the control unit 13 and can be abutted there via the teacher system 7:

- Malfunctions (special errors that are imported by the teacher system during an exercise)

- scenarios (compilation of events in the run-up to a training session)

- Record / Play (record and play sessions with the option to continue a session) - Student ratings

In order to change values of internal status data of the process simulator (2), bypassing the recording and input device (8), the teacher system (7) can be coupled directly to the process simulator (2) via a further communication interface 18, preferably also a UDP interface , Via this interface 18 model and simulation data can be exchanged directly between the process simulator 2 and the teacher system 7. In this way it is possible for a teacher to manipulate simulation data directly via the teacher system 7. The data exchange between the teacher system 7 and the process simulator 2 is controlled via an I / O server 19. For example, a teacher may change the value of oil pressure in process simulator 2. The process simulator 2 converts this value into a corresponding raw value according to the encoder type. An affected SoftPLC instance 9 of the control simulator 3 cyclically executes the original control program of the automation system and reads in this raw value. The control program recognizes a change in the measured value (and possibly an alarm) and transmits the current process states to the visualization 4, whereupon the process images are updated to the corresponding output components 5. FIG. 2 shows a possible hardware system configuration for the training system 1 of FIG. 1. A training system 20 comprises a plurality of student workstations 21 in the form of a PC or notebook, a process simulation computer 22 for process simulation, an emulation computer 23 for simulation of the controller, and a teacher workstation 24 in the form a PC or notebook. The process simulation computer 22 and the emulation computer 23 can also be combined in a single computer. The workstations 21, 24 and the computers 22, 23 can communicate with each other via a communication bus 25.

The visualization (HMI) 4 of FIG. 1 is installed on all student workstations 21. The SoftPLC instances 9 of FIG. 1 run on the emulation computer 23. The teacher's workstation 24 of FIG. 1 is available on the teacher's workstation 24.

A component of an automation system, in particular a ship automation system, are decentralized local operator panels (LOP). The integration of such operator panels in the simulation can be realized differently. However, the communication between such an operator panel and the SoftPLCs preferably takes place via the process simulator.

In a training system 30 shown in FIG. 3, the original device is used as the on-site operating device 31, and the process simulation computer 22 is coupled to the operating device 31 via an additional interface 32 with a bus interface, for example a Profibus interface. The process simulation computer 22 controls the incoming and outgoing data via the interface 32. The function and operation of the operating device 31 is identical to the original device. In a training system 40 shown in FIG. 4, the operating device is simulated in the process simulation computer 22 and runs on a separate computer 41. In this case, the basic function of the operating device is simulated in the process simulation computer 22. The HMI device can then access the SoftPLCs in the emulation computer 23 directly and read the required data directly from the data blocks of the SoftPLCs. In addition, the HMI device can be integrated with the process simulation computer 22.

A further possibility, illustrated in FIG. 5, is that the operating device is simulated in a training system 50 as a graphical user interface on a separate computer 51. The appearance for the operator preferably corresponds to that of the original device. Operation is via input devices (for example a mouse) or directly via a touch screen. The functionality of the HMI device is implemented in a programming language (for example JAVA or C ++). The communication with the training system takes place via the process simulation computer 22 by means of UPD or OPC.

Claims

claims

A training system (1) for an automation system for controlling a technical process, in particular a ship's automation system

a process simulator (2) for simulating the technical process and for generating process data (P) as a function of control data (S) and

- A control simulator (3) for generating the control data (S) for the process simulator (2) and output data (A) for one or more output components (5) of the training system (1) by simulation of the control units of the automation system in dependence on the process data ( P) and input data (E) of input components (6) of the training system (1), characterized by a recording and input device (8) for receiving the output data (A), the input data (E), internal control state data (SZ) of the control simulator (3) and internal process state data (PZ) of the process simulator (2) and for recording the recorded output data (A) in the output components (5), the input data (E) and the internal control state data (SZ) in the control simulator (3) and the internal process state data (PZ) into the process simulator (2).

2. training system (1) according to claim 1, characterized in that the recording and Einspieleinrichtung (8) at least one recording and input unit (14 or 15) for the data recording and recording and a control unit (13) for controlling the data recording and -einspielung.

3. Training system (1) according to any one of the preceding claims, characterized in that the control unit (13) with a teacher system (7) for controlling the data recording and recording by the teacher system (7) can be coupled.

4. training system (1) according to claim 3, characterized in that the teacher system (7) for changing values of internal state data of the process simulator (2), bypassing the recording and input device (8) directly coupled to the process simulator (2) is.

5. training system (1) according to one of the preceding claims, characterized in that the recording and Einspieleinrichtung (8) is designed such that the recording of the output data (A) and the input data (E) with a higher frequency than the recording of the internal control state data (SZ) and the internal process state data (PZ) takes place.

6. training system (1) according to one of the preceding claims che, characterized in that control devices of the automation system in the control simulator (3) are simulated by a software emulation.

7. Training system (1) according to one of the preceding claims, characterized in that a local on-site

Control unit (31) with the process simulator (2) can be coupled.

8. training system (1) according to one of claims 1 to 6, characterized in that a local on-site control unit in the process simulator (2) is simulated.

9. Training system (1) according to one of claims 1 to 6, characterized in that a local on-site operating device is simulated as a graphical user interface on a separate computer (51) of the training system.