Simulation Device and Method for Virtually Testing a System Control Process

Abstract

A method for virtually testing a system control process for a process engineering system and a simulation device for virtually testing the system control process, wherein at least one preconfigured control module for controlling a component of the system is provided and the system control process is generated based on this control module and the control of the process engineering system is additionally simulated by the generated system control process, where at least one value of an input parameter of the system control process is predefined by a component-specific simulation model, and where the component-specific simulation model is contained in the preconfigured control module.

Claims

1.-13. (canceled)

14. A method for virtually testing a system control for a process engineering system, the method comprising: providing at least one preconfigured control module which controls a component of the process engineering system; generating the system control based on said at least one preconfigured control module; and simulating the control of the process engineering system via the generated system control, at least one value of an input parameter of the system control being predefined by a component-specific simulation model; wherein the component-specific simulation model is contained in the at least one preconfigured control module.

15. The method as claimed in claim 14, wherein at least one value predefined within the at least one preconfigured control module by the component-specific simulation model induces the provided at least one preconfigured control module to simulated control of the component of the process engineering system.

16. The method as claimed in claim 14, wherein behavior of the component of the process engineering system is mapped via at least one value predefined within the at least one preconfigured control module by the component-specific simulation model.

17. The method as claimed in claim 15, wherein behavior of the component of the process engineering system is mapped via at least one value predefined within the control module by the component-specific simulation model.

18. The method as claimed in claim 14, wherein the at least one value predefined within the at least one preconfigured control module by the component-specific simulation model depends on a further component of the process engineering system.

19. The method as claimed in claim 14, wherein at least one value is predefined within the provided at least one control module by the component-specific simulation model based on a parameter of the provided at least one preconfigured control module.

20. The method as claimed in claim 14, wherein at least one value is predefined within the provided at least one preconfigured control module by the component-specific simulation model based on an output variable, which the provided at least one preconfigured control module outputs for controlling the component.

21. The method as claimed in claim 14, wherein at least one output value of a mathematical function is predefined as the at least one value by the component-specific simulation model.

22. The method as claimed in claim 14, further comprising: adjusting the component-specific simulation model contained in the at least one preconfigured control module to physical properties of the component of the process engineering system.

23. The method as claimed in claim 22, further comprising: pre-configuring the at least one control module; wherein the component-specific simulation model contained in the at least one preconfigured control module is adjusted to the pre-configuration.

24. The method as claimed in claim 22, wherein one of a plurality of variants of the at least one preconfigured control module is provided and the component-specific simulation model contained in the at least one preconfigured control module is adapted to the provided variant.

25. The method as claimed in claim 23, wherein one of a plurality of variants of the at least one preconfigured control module is provided and the component-specific simulation model contained in the at least one preconfigured control module is adapted to the provided variant.

26. The method as claimed in claim 22, wherein the component-specific simulation model is automatically adjusted.

27. The method as claimed in claim 23, wherein the component-specific simulation model is automatically adjusted.

28. The method as claimed in claim 24, wherein the component-specific simulation model is automatically adjusted.

29. The method as claimed in claim 14, wherein the at least one preconfigured control module is provided in a generic format in which the component-specific simulation model is readable from the provided at least one preconfigured control module that has been and utilizable by a system simulator for generation of at least one value for an input parameter E of the at least one preconfigured control module.

30. A simulation device for virtually testing a system control for a process engineering system, comprising: a processor; and memory; wherein the simulation device is configured to: providing at least one preconfigured control module which controls a component of the process engineering system; generating the system control based on said at least one preconfigured control module; and simulating the control of the process engineering system via the generated system control, at least one value of an input parameter of the system control being predefined by a component-specific simulation model; wherein the component-specific simulation model is contained in the at least one preconfigured control module.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The invention will be explained in more detail below with reference to figures. In the drawings, at least partially schematically:

[0042] FIG. 1 shows an exemplary flowchart of a method for testing a system control for a process engineering system in accordance with the invention; and

[0043] FIG. 2 shows an an exemplary control module for controlling a component of a system with a simulation model of the component in accordance with the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0044] FIG. 1 shows an example of a method 100, in particular an at least partially computer-implemented one, for virtually testing a system control 1 for a process engineering system, for instance a refinery or factory. The system control 1 is assembled at least partially from pre-configured control modules 2, which are each adapted to control a component of the system, such as a valve, an actuator, and/or a sensor, and can be provided, as required, in different phases of the development process of a processing engineering system, in particular a planning phase 10 for design of the process engineering system and/or a development phase 20 for creating the system control 1. The control modules 2 contain simulation models 13 of the component of the system, based on which the control of the system by the system control 1 can be simulated.

[0045] The pre-configured control modules 2, such as modular, component-specific control software units, which each contain the control software for one component of the system, are provided in a method step S1a, S1b. Different types of components, which the system should comprise, can be defined and, such as their properties established, in the planning and/or development phase 20, optionally in a preceding method step (not shown). During provision S1a, S1b of the control modules 2 preferably different variants of these pre-configured control modules 2 are then each provided which, owing to their slightly differing configurations, can fulfil specific functions, such as according to the arrangement of the components within the system. This provision S1a, S1b of different variants of a generic control module 2 can also be referred to as instantiation.

[0046] In a further method step S2, the control modules 2 are assembled to form the system control 1. This preferably occurs in the development phase 20. The control modules 2 can be specified further, for example be adjusted to demands and/or dependencies of different components of the system on each other, resulting during creation of the system control 1. In particular, if necessary, further control modules 2 can also be instantiated.

[0047] The system control 1 generated in this way can then be tested based on a virtual model of the system, in other words, within the framework of a simulation. The simulation is preferably performed based on the simulation models 3 of the components of the system, with an overall model of the system being at least partially assembled from the individual simulation models 3. Control of the system via the previously generated system control 1 is simulated in a further method step S3, where it is possible for the implementation of the system control 1 based on the simulated system model, assembled at least partially from the simulation models 3, to also be referred to as emulation.

[0048] Values for input parameters E of the system control 1 are required for emulation of the system control 1. For example, measured values of a sensor are required for pressure measurement in order to be able to generate a control signal for controlling a valve as a function of the measured values, or the manipulated variable of a valve is required in order to be able to generate a control signal for an actuator as a function of the manipulated variable. Such values can be generated and provided in method step S3 based on the simulated overall model of the system or the simulation models 3 of the individual components of the system in order to be incorporated and processed by the system control 1. The control signals, generated by the system control, for the components of the system or other output variables A can likewise be provided in order to be incorporated by the simulation models 3 and for generating further values for the input parameters E of the system control 1. The feedback that can thus be generated corresponds precisely to the simulation S3 of the control of the processing engineering system by the system control 1.

[0049] Here, it is particularly advantageous to contain the simulation models 3 in the control modules 2, as is indicated by the dot-dash connecting line in FIG. 1. Because, as a result, the simulation models 3 can be pre-configured substantially at the same time as the control modules 2, in particular during the planning and/or development phase 10, 20. For example, it is conceivable to define the simulation models 3, together with the control modules 2, directly in the method step (not shown) directly before providing Sla, S1b of the control modules 2 and to optionally specify them analogously to the control modules 2 in accordance with the functionality and arrangement of the corresponding component in the system. This increases the efficiency of virtually testing the system control 1 because, with a subsequent configuring of the simulation models 3, in particular after the system control 1 has already been created in method step S2, the clarity can be impaired.

[0050] Alternatively or in addition, it is also conceivable to adjust the simulation models 3 during provision Sla, S1b of the pre-configured control modules 2, for example, to the respective control module 2 and/or to supplement aspects, which are established in the respective phase 10, 20, such as the process engineering-related connection between two components.

[0051] FIG. 2 shows an exemplary control module 2 for controlling a component of a process engineering system, where the control module 2 contains a simulation model 3 of the component. The control module 2 is preferably characterized by a control unit (processor) 2a, which implements the control logic, in other words, for example, processes values of input parameters E and on the basis thereof provides output variables A, such as control signals for controlling the component. The control unit 2a can include, in particular, software code, such as a script stored in memory of the control unit 2a. In a particularly preferred embodiment, the control unit 2a implements a Continuous Function Chart (CFC) with which even complex control tasks and/or feedback control problems can be mapped or implemented.

[0052] The control module 2 can also contain parameters 2b on the basis of which the, preferably generic, control logic of the control module 2, such as the continuous function chart, can be implemented. The parameters 2b can be, for instance, prefactors of a mathematical function, which maps the control logic and is implemented by the control unit 2a.

[0053] The control unit 2a can, for example, implement a proportional-integral-differential (PID) control, with three parameters 2b being used as prefactors of the proportional, integral and differential elements of the control.

[0054] While, as a rule, the control unit 2a is not adjusted in the framework of the development process of the system control but is generic for a particular type of component, such as a valve, the parameters 2b can be adjusted in the different phases of the development process, such as to the intended effect of the corresponding component within the system. Adjusting the parameters 2b can be part of a pre-configuring of the control module 2.

[0055] An output variable A, generated by the control unit 2a, such as in the form of a control signal, does not have to be used exclusively for controlling the component that is assigned to the control module 2. A different component can optionally also be controlled based on such control signals, in particular if it is connected to the component, to which the control module 2 is assigned, in terms of process engineering. It is conceivable, for example, that a control signal generated by a control unit 2a of the control module 2 of a controller is used for controlling an actuator. This is indicated by the broken-line arrow A′.

[0056] As indicated in FIG. 2, the values for input parameters E of the control unit 2a are preferably provided by the simulation model 3 within the control module 2. These can be, for example, (simulated) output signals of the component, for instance of a sensor, on the basis of which the control unit 2a can generate a control signal in the form of a value of the output variable A. Alternatively, the value of an input parameter E can also simply be a manipulated variable of the component, for example, of a valve, which is to be considered on generation of a control signal by the control unit 2a. In particular, the value of an input parameter E can characterize the (operating) state of the component.

[0057] In addition, the component, in particular within an overall simulation of the processing engineering system, can be simulated based on the simulation model 3. For this purpose, the simulation model 3 preferably has a simulation unit 3a, which maps the behavior of the component, in other words processes, for example, output variables A of a control unit 2a, such as in the form of control signals and on the basis thereof provides values of input parameters E. The simulation unit 3a can be formed, in particular, by software code, for example, as a script. In a particularly preferred embodiment, the simulation unit 3a comprises a mathematical function, which maps the behavior of the component. Alternatively or in addition, the simulation unit 3a can also comprise other forms of behavioral descriptions, however, such as continuous function charts.

[0058] In addition to the control signals, the behavior of the component can also be affected by external influences A″. These can be, for example, process conditions of the process performed by the process engineering system. The simulation unit 3a can thus consider, for example, which temperature and/or which pressure the component is exposed to and/or how high is the flow rate of a process fluid.

[0059] Optionally, the simulation unit 3a can also be adapted to consider the process engineering-related connection with further (simulated) components of the system. For example, control signals from a control module 2 of a controller can be considered in the case of simulation of an actuator. This is indicated by the broken-line arrow A′″.

[0060] Preferably, in addition to output variables A of the control unit 2a in the form of control signals, the simulation unit 3a also considers the parameters 2b of the control module 2 at least insofar as they are relevant to the simulation of the component. This can be the case, for example, if the component exhibits damped behavior and this damped behavior, which is characterized by a parameter 2b, is considered when controlling the component by incorporating this parameter 2b.

[0061] This embodiment shows particularly clearly the advantage of a control module 2 for controlling a component in which the simulation model 3 of the component is integrated. Because both control unit 2a and simulation unit 3a refer at least partially to the same parameter 2b, by adjusting the parameter, for instance, in the case of instantiation of control module 2 in the development phase, the simulation model 3 is also pre-configured at the same time as the control module 2. A separate, independent adjustment step of the simulation model, as is necessary in the prior art, can be omitted, such that the efficiency of the development process of the process engineering system, in particular of testing of the system control, is increased.

[0062] And even if adjustments of the simulation model 3 are necessary, which are not automatically implemented via a configuration of the control module 2 or the control unit 2a, for example, of a continuous function chart, the integration of the simulation model 3 in the control module 2 is advantageous in respect of the clarity of the development process of the system, in particular of testing of the system control. This is because as a result of the fact that when providing, for example, a variant of the pre-configured control module 2, a corresponding simulation model 2 is also automatically provided, firstly it is no longer necessary to subsequently ascertain how many simulation models have to be generated at all in order to make it possible to emulate the system control. Secondly, an easily comprehensible assignment of simulation model 3 to control module 2 is generated as a result.

[0063] Thus, while there have been shown, described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the methods described and the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.