WO2002079885A2 - Maintenance method and device with a simulation model - Google Patents
Maintenance method and device with a simulation model Download PDFInfo
- Publication number
- WO2002079885A2 WO2002079885A2 PCT/DE2002/001013 DE0201013W WO02079885A2 WO 2002079885 A2 WO2002079885 A2 WO 2002079885A2 DE 0201013 W DE0201013 W DE 0201013W WO 02079885 A2 WO02079885 A2 WO 02079885A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- simulation
- real
- real process
- maintenance
- simulation process
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 121
- 238000004088 simulation Methods 0.000 title claims abstract description 55
- 238000012423 maintenance Methods 0.000 title claims abstract description 25
- 230000001360 synchronised effect Effects 0.000 claims abstract description 3
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 230000000977 initiatory effect Effects 0.000 claims description 2
- 230000004913 activation Effects 0.000 claims 1
- 238000004886 process control Methods 0.000 abstract 1
- 239000000126 substance Substances 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 5
- 238000011049 filling Methods 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 230000001960 triggered effect Effects 0.000 description 3
- 238000003756 stirring Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000010411 cooking Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 230000026676 system process Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0243—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32343—Derive control behaviour, decisions from simulation, behaviour modelling
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32356—For diagnostics
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32385—What is simulated, manufacturing process and compare results with real process
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- 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.
- complex systems are often monitored by sensors and the measured values are used to identify maintenance needs.
- 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.
- the pressure in a system can increase over time, which indicates, for example, a blockage in a pipeline.
- vibrations can draw conclusions about bearing wear or the measurement of the phase angle triangle in a drive can indicate an unfavorable slip.
- 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.
- 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.
- 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.
- FIG. 1 shows a data flow diagram of a real process and a parallel simulation process according to the invention
- 3 shows a signal flow plan for carrying out maintenance measures.
- FIG. 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
- sequence logic 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.
- 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.
- 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,
- a corresponding simulation process is shown in the right-hand side of the image in FIG.
- 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.
- the pipe master data reflect 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 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.
- 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.
- 3 3 d d d 3 CQ 3 3 3 CQ tr ⁇ d ⁇ ⁇ 3 d ⁇ rt ⁇ P- P ⁇ ⁇ J rt tr rt
- 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.
- 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.
- 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.
- SIMIT receives 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.).
- equipment behavior e.g. resistance heating element
- 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.
- Objects are the "machines" of the system model.
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Manufacturing & Machinery (AREA)
- General Engineering & Computer Science (AREA)
- Quality & Reliability (AREA)
- Testing And Monitoring For Control Systems (AREA)
- Exposure And Positioning Against Photoresist Photosensitive Materials (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP02724114A EP1373998A2 (en) | 2001-03-29 | 2002-03-20 | Maintenance method and device with a simulation model |
US10/670,929 US20050187663A1 (en) | 2001-03-29 | 2003-09-25 | Maintenance method and device |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10115694.4 | 2001-03-29 | ||
DE10115694 | 2001-03-29 | ||
DE10147741.4 | 2001-09-27 | ||
DE10147741A DE10147741A1 (en) | 2001-03-29 | 2001-09-27 | Maintenance method and apparatus |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/670,929 Continuation US20050187663A1 (en) | 2001-03-29 | 2003-09-25 | Maintenance method and device |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2002079885A2 true WO2002079885A2 (en) | 2002-10-10 |
WO2002079885A3 WO2002079885A3 (en) | 2003-08-07 |
Family
ID=26008957
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/DE2002/001013 WO2002079885A2 (en) | 2001-03-29 | 2002-03-20 | Maintenance method and device with a simulation model |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP1373998A2 (en) |
WO (1) | WO2002079885A2 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2010094359A1 (en) * | 2009-02-17 | 2010-08-26 | Siemens Aktiengesellschaft | Method and system for engineering an automation of at least part of a technical installation |
WO2012031859A1 (en) * | 2010-09-06 | 2012-03-15 | Siemens Aktiengesellschaft | Control device for a factory installation, and control and monitoring methods for such a factory installation |
EP2479630A1 (en) * | 2011-01-25 | 2012-07-25 | Siemens Aktiengesellschaft | Method for collision-free switching of an assembly from off mode to operational mode |
WO2013009610A1 (en) * | 2011-07-08 | 2013-01-17 | Intelligrated Headquarters Llc | Integrated simulation technology |
EP3144751B1 (en) * | 2015-09-18 | 2021-10-27 | Siemens Aktiengesellschaft | Control system, and method for operating a control system with a real and a virtual controller for process monitoring |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0643344A1 (en) * | 1993-07-19 | 1995-03-15 | Texas Instruments Incorporated | Apparatus and method for model based process control |
DE19639424A1 (en) * | 1995-09-25 | 1997-03-27 | Siemens Ag | Ind. plant atomisation design system using combined process and control model |
US5752008A (en) * | 1996-05-28 | 1998-05-12 | Fisher-Rosemount Systems, Inc. | Real-time process control simulation method and apparatus |
US6088630A (en) * | 1997-11-19 | 2000-07-11 | Olin Corporation | Automatic control system for unit operation |
EP1061422A1 (en) * | 1999-06-11 | 2000-12-20 | IvyTeam AG | Computer system for the definition, optimisation and control of processes |
WO2001001207A1 (en) * | 1999-06-30 | 2001-01-04 | Etec Systems, Inc. | Method and apparatus for hierarchical control of continuously operating systems |
-
2002
- 2002-03-20 WO PCT/DE2002/001013 patent/WO2002079885A2/en not_active Application Discontinuation
- 2002-03-20 EP EP02724114A patent/EP1373998A2/en not_active Ceased
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0643344A1 (en) * | 1993-07-19 | 1995-03-15 | Texas Instruments Incorporated | Apparatus and method for model based process control |
DE19639424A1 (en) * | 1995-09-25 | 1997-03-27 | Siemens Ag | Ind. plant atomisation design system using combined process and control model |
US5752008A (en) * | 1996-05-28 | 1998-05-12 | Fisher-Rosemount Systems, Inc. | Real-time process control simulation method and apparatus |
US6088630A (en) * | 1997-11-19 | 2000-07-11 | Olin Corporation | Automatic control system for unit operation |
EP1061422A1 (en) * | 1999-06-11 | 2000-12-20 | IvyTeam AG | Computer system for the definition, optimisation and control of processes |
WO2001001207A1 (en) * | 1999-06-30 | 2001-01-04 | Etec Systems, Inc. | Method and apparatus for hierarchical control of continuously operating systems |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2010094359A1 (en) * | 2009-02-17 | 2010-08-26 | Siemens Aktiengesellschaft | Method and system for engineering an automation of at least part of a technical installation |
WO2012031859A1 (en) * | 2010-09-06 | 2012-03-15 | Siemens Aktiengesellschaft | Control device for a factory installation, and control and monitoring methods for such a factory installation |
EP2479630A1 (en) * | 2011-01-25 | 2012-07-25 | Siemens Aktiengesellschaft | Method for collision-free switching of an assembly from off mode to operational mode |
US9122271B2 (en) | 2011-01-25 | 2015-09-01 | Siemens Aktiengesellschaft | Method for collision-free transfer of a plant from an substantially off mode to an operating mode |
WO2013009610A1 (en) * | 2011-07-08 | 2013-01-17 | Intelligrated Headquarters Llc | Integrated simulation technology |
US8731722B2 (en) | 2011-07-08 | 2014-05-20 | Intelligrated Headquarters Llc | Integrated simulation technology |
US9280619B2 (en) | 2011-07-08 | 2016-03-08 | Intelligrated Headquarters, Llc | Integrated simulation technology |
EP3144751B1 (en) * | 2015-09-18 | 2021-10-27 | Siemens Aktiengesellschaft | Control system, and method for operating a control system with a real and a virtual controller for process monitoring |
Also Published As
Publication number | Publication date |
---|---|
EP1373998A2 (en) | 2004-01-02 |
WO2002079885A3 (en) | 2003-08-07 |
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