The disclosure is directed to a novel system and methods for modeling process components using segmental analysis. As opposed to analyzing the entire system at once, each element representing a process component is assigned parameter inputs that enable the system to determine a current state. Changes in the element's parameter inputs are fed in a bi-directional manner to other elements connected by segments where the other elements use the parameter inputs to determine a predictive or current process condition that are used as new parameter inputs for the next element. In some embodiments, the system allows for the prevention of component state change with only a portion of the entire process being solved, as abnormal conditions can be detected without solving for the entire system.

A system for using digital twins to interact with physical objects in an automation system includes a plurality of controller devices, a process image backbone, and a registry comprising a plurality of digital twins. Each respective controller device comprises a volatile computer-readable storage medium comprising a process image area. The process image backbone provides the controllers with uniform access to the process image area of each controller. Each digital twin in the registry corresponds to a physical device controllable via one of the controllers devices via a corresponding process image area.

A system for using digital twins to interact with physical objects in an automation system includes a plurality of controller devices, a process image backbone, and a registry comprising a plurality of digital twins. Each respective controller device comprises a volatile computer-readable storage medium comprising a process image area. The process image backbone provides the controllers with uniform access to the process image area of each controller. Each digital twin in the registry corresponds to a physical device controllable via one of the controllers devices via a corresponding process image area.