WO2002079885A2

WO2002079885A2 - Maintenance method and device with a simulation model

Info

Publication number: WO2002079885A2
Application number: PCT/DE2002/001013
Authority: WO
Inventors: Lueder Heidemann; Hansjürgen SEYBOLD
Original assignee: Siemens Aktiengesellschaft
Priority date: 2001-03-29
Filing date: 2002-03-20
Publication date: 2002-10-10
Also published as: EP1373998A2; WO2002079885A3

Abstract

A real process is simulated for preventively detecting the need for maintenance and the simulation is synchronized with the real process. Malfunctioning can be timely detected from a process control viewpoint by comparing the real process with the simulation and maintenance measures can be appropriately managed. Downtime in a facility can thus be reduced and individual process steps are optimized.

Description

description

Maintenance method and apparatus

The present invention relates to an apparatus and a method for maintaining a system process is processed in the ^'a real.

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. For this purpose, measured values of system components are typically 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 draw conclusions about 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, very compact plant construction or excessive complexity of individual components can be uneconomical. The object of the present invention is therefore to improve or expand the possibilities for recognizing the need for maintenance of plants and systems.

According to the invention, this object is achieved by a method for maintaining a system by executing a real process in the system, executing a simulation process in parallel with the real process, the simulation process simulating at least part of the real process, comparing the simulation process with the real process or the part of which with gaining a comparison result and deriving maintenance measures from the comparison result.

Furthermore, the above-mentioned object is achieved by a device for the maintenance of a system on which a real process can be carried out with one or more real process steps, with a simulation device for simulating at least part of the real process by means of a simulation process, the simulation process being parallel to the time Real process is executable, a comparison device for comparing the simulation process with the real process to obtain a comparison result and a control device for initiating a maintenance measure on the basis of the comparison result.

Production-driven maintenance can thus advantageously be made possible with the invention, with the simulation of the process running parallel to the real process. The simulation process can be supplied with associated production parameters, for example.

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

3 shows a signal flow plan for carrying out 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 for both

Batch processing processes as well as suitable for continuous processes.

The actual system control or automation takes place in the block labeled “sequence logic” in FIG. 1. A separate module between the recipe control and the sequence logic ensures the coordination of the commands with regard to the semantics.

The logic sequence is connected to several function blocks FB, which are responsible for the automation of the individual steps. The sequence logic and the function blocks then exchange commands and measured values with the process components of the real process via an input / output periphery. A simple production process that is carried out in a simplified system could serve as an example of a real process. A container is connected to a reactor via a pipe. There are two units in the reactor, a stirrer and a heating unit. The container is filled with a certain substance. During the production process, the reactor could be filled with the substance from the container and then the heated substance could be heated and stirred. The corresponding process steps are filling, heating and stirring. Each of these individual process steps or basic operations has its own internal sequence of command steps, which is implemented in the logic sequence. For example, the filling process step can include the commands: check the state of the rotary valve, open the slide, check the filling level, etc. The individual process steps are precisely defined in a recipe for the production of a specific substance. Similar to a cooking recipe, the control recipe contains parameters such as process times,

Process temperatures, etc. In addition, a certain sequence of process steps is specified.

In the logic sequence, the individual process steps are sequenced and the respective start and end are fixed in time. If the sequence logic is specified, function blocks take over the individual control of system components.

A corresponding simulation process is shown in the right-hand side of the image in FIG. 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 means of suitable interconnection of the equipment simulation modules.

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

Equipment master data, substance master data, pipe 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 dimensions and other relevant sizes of the pipes used. All master data can be stored in libraries.

According to the invention, 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 is not necessary to simulate the entire real process, for example, a particularly critical process step that, for example, requires constant monitoring can be simulated.

The process simulation is advantageously controlled by the order control of the real process. However, a separate control can also be provided for the simulation. In addition, the process simulation preferably obtains the recipes from the recipe management of the real process. This direct connection to the real process is a prerequisite for an automatic engineering of the simulation. In any case, it is extremely helpful for this.

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and actual system is good / bad and (with process simulation) allocation to asset.

Evaluation behavior Compare value from archive plant behavior or from plant behavior (with fixed values that are determined during IBS / trial operation) with real plant results. Otherwise as above.

Annotation:

Evaluation Simulation is advantageous for multi-purpose systems in which a meaningful archive of system behavior is not guaranteed due to the variety of products / recipes.

Evaluation of behavior is advantageous for "single-purpose" systems and continuous / semi-continuous systems.

Process simulation Technological monitoring of recipe steps SIMIT has models of GO's systems (stirring, heating, filling, etc.). Each individual model has parameters (substance, unit and product parameters). The SI- mulation 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 GO defined result parameter set to Diag.

SIMIT does not (yet) master substance conversions, such operations (eg "reaction", "synthesis") have to be simulated using simple empirical equations if several GOs are to be run 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.

Receiving equipment Technological monitoring of equipment behavior SIMIT has models of (technological) equipment behavior (e.g. resistance heating element) Time behavior, heat transfer, heat flow in the material, etc.).

Otherwise analogous as above

Arch Archive Plant behavior History of the product and substance / material-dependent time behavior of sub-plants, units, equipment and corresponding (fixed) parameters.

Different forms in process and discrete (manufacturing) industry:

Process industry: Objects are process steps e.g. B. filling, heating, etc. and equipment (S 88), not the objects of the system model z. B. pump, control valve etc.

Discrete industry: Objects are the "machines" of the system model.

Claims

claims

1. Procedure for maintaining a system

Executing a real process in the system,

marked by

Execution of a simulation process 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.

2. The method according to claim 1, wherein synchronization with the real process takes place for executing the simulation process.

3. The method according to claim 1 or 2, wherein the simulation process and the real process each comprise several steps and at least one of the steps for deriving maintenance measures are compared with each other.

4. The method according to any one of claims 1 to 3, wherein the comparison is carried out on the basis of the final results of the real process and the simulation process relating in particular procedural variables and / or partial results of one or more steps of the real process and the simulation process relating in particular procedural variables.

5. The method according to any one of claims 1 to 4, wherein the real process and the simulation process together by one single control device can be controlled.

6. The method according to any one of claims 1 to 5, wherein a maintenance measure is an alarm and / or an activation of a maintenance system.

7. The method according to any one of claims 1 to 6, wherein a simulation process structure is automatically generated from a real process structure, in particular using a generic simulation model.

8. The method according to any one of claims 1 to 7, wherein the simulation process is supplied with material and / or production parameters from the real process.

9. Device for the maintenance of a system on which a real process can be carried out with one or more real process steps,

marked by

a simulation device for simulating at least a part of the real process by means of a simulation process, the simulation process being able to be executed in parallel with the real process,

a comparison device for comparing the simulation process with the real process to win a win. result and

a control device for initiating a maintenance measure based on the comparison result.

10. The device according to claim 9, wherein the simulation process in the simulation device can be synchronized with the real process.

11. The device according to claim 9 or 10, wherein the simulation process and the real process each comprise several steps and at least one of the steps in the comparison device can be compared with each other.

12. The device according to one of claims 9 to 11, wherein in the comparison device, the comparison can be carried out on the basis of final results of the real process and the simulation process, in particular with regard to procedural variables, and / or partial results of one or more steps of the real process and the simulation process, in particular with regard to procedural variables ,

13. Device according to one of claims 9 to 12, wherein the real process and the simulation process can be controlled together by a single control device.

14. Device according to one of claims 9 to 13, which is embedded in a maintenance system.

15. Device according to one of claims 9 to 14, wherein a simulation process structure can be generated automatically from a real process structure, in particular using a generic simulation model.

16. The device according to one of claims 9 to 15, wherein the simulation device can be supplied with production parameters from the real process.