Method for Engineering and Simulating an Automation System via Digital Twins

Abstract

A method for engineering an automation system that is usually tested before being put into operation, wherein a “twin” or a virtual component is generated and loaded onto a server for each real component to perform the function of the real components in a simulated manner in place of said real components, such that it is thus possible for a user to replace various real components with virtual components during the engineering process and to check or simulate the function of the automation system, where it becomes possible to perform a synchronous optimization of automation systems or to put automation programs and system displays into operation in a coexistent, safe, flexible, and incremental manner.

Claims

1.-11. (canceled)

12. A method for engineering an automation system for controlling a process in a technical plant, the automation system comprising a plurality of hardware components for performing display, operating and automation functions, said plurality of hardware components being interconnected via communication systems, the method comprising: virtualizing, generating as a coexistent digital twin, instantiating and logically linking, in parallel with engineering of at least one real hardware component, said at least one real hardware component with other virtual or real components; and distributing generated virtual components in any desired manner onto servers of the automation system such the generated virtual components are configured, optimized and monitored by at least one client and such that, during engineering, switching between real components and virtual components to perform changes becomes possible.

13. The method as claimed in claim 12, wherein the switchover occurs with a cycle of the automation system.

14. The method as claimed in claim 12, wherein distribution of the virtual components onto the servers of the automation system is configurable.

15. The method as claimed in claim 13, wherein distribution of the virtual components onto the servers of the automation system is configurable.

16. The method as claimed in claim 12, wherein a number of virtual components is freely selectable.

17. The method as claimed in claim 13, wherein a number of virtual components is freely selectable.

18. The method as claimed in claim 14, wherein a number of virtual components is freely selectable.

19. The method as claimed in claim 12, wherein logical connections for communication between the virtual components and additionally between virtual and the real components are configurable.

20. The method as claimed in claim 12, wherein the virtual are managed in a database.

21. The method as claimed in claim 12, wherein the virtual components are allocated to a technological hierarchy such that a definition of which plant components are automated by which device is established.

22. The method as claimed in claim 12, wherein functional plans or plant images for a commissioning are allocated to the virtual components before said virtual components are loaded onto the servers of the automation system in parallel with real components.

23. An automation system for controlling a process in a technical plant, the automation system comprising: a plurality of hardware components for performing display and operating functions and automation functions, said plurality of hardware components being interconnected via communication systems, an engineering server for configuring each of the plurality of hardware components; and at least one further server; wherein the servers are configured to: virtualize, generate as a coexistent digital twin, instantiate and logically link, in parallel with engineering of at least one real hardware component, said at least one real hardware component with other virtual or real components; and distribute generated virtual components in any desired manner onto servers of the automation system such the generated virtual components are configured, optimized and monitored by at least one client and such that, during engineering, switching between real components and virtual components to perform changes becomes possible.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention and its embodiments are described and explained in more detail below on the basis of the figures, in which an exemplary embodiment of the invention is shown and, in which:

[0025] FIG. 1 shows a functional schematic diagram of an automation system for controlling a process with the software architecture indicated for implementing the inventive method in accordance with an embodiment of an optimization in parallel with operation;

[0026] FIG. 2 shows a further functional diagram of an automation system for controlling a process with the software architecture indicated for implementing the inventive method in accordance with an embodiment of a staged commissioning; and

[0027] FIG. 2 is a flowchart of the method in accordance with the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0028] FIG. 1 shows a simplified schematic representation of an example of an automation system A, via which mostly process engineering in a technical plant, e.g., a technical manufacturing, production or also power plant, is controlled, regulated and monitored. The automation system A has a plurality of process-oriented components (field devices, assemblies, I/O systems, controllers) that perform specific measurement, control and regulation functions on the field level, i.e., in the process. The field devices exchange process-, function- and/or device-relevant data with one another via a communication system (here Profibus TB), and with the higher control and command levels. The communication system of the field level is connected with a plurality of automation devices AS such as programmable logic controllers (PLCs). The automation devices AS1, AS2 are in turn connected with a higher-level computer system via a further communication system, the plant bus AB, which is in most cases formed as an Industrial Ethernet. In the present exemplary embodiment, this comprises an operating and monitoring system, which consists of a number of operator station servers OS (abbreviated to OS servers, OS1, OS2 . . . ) and at least one client computer. The OS client OSC exchanges information and data with the OS servers via a further bus system TB, which is referred to here as a terminal bus TB. Furthermore, the automation system can comprise even more servers. The automation system shown in FIG. 1 is configured such that it has a further component, an engineering workstation ES. This is a computer or server, which is connected to the communication systems AB and TB for data transmission purposes and can likewise access the communication systems AB and TB via a client of the operating and monitoring system. If necessary, even more computers or servers S can be connected to the communication systems AB and TB.

[0029] FIG. 1 also shows in simplified form, besides parts of the hardware configuration of the automation system just described, parts of the software architecture for implementing the inventive method.

[0030] In accordance with the invention, virtual components of the real afore-described hardware configuration are shown in the engineering server ES, embodied as software modules or software components.

[0031] FIG. 1 shows by way of example a functional diagram of a coexistent digital twin for an optimization in parallel with operation. Virtual counterparts, the virtual components (VOS1, VOS2, VAS1, VAS2), exist for each of the real devices (operator station servers OS1, OS2, automation devices AS1, AS2 . . . ). The logical connections between the real components are symbolized with thick black lines. The logical connections between the virtual components are symbolized by dashed lines. On account of the logical connections, a client can switch flexibly between the real plant and the digital twin. Both the real plant and also the digital twin are configured and monitored by the integrated engineering. The field level is virtualized by the plant simulator SIMIT.

[0032] By applying the inventive measures, it is now possible to co-existently plan virtual automations and operator station servers in the engineering, such that it is possible to switch between real and virtual plant sections during runtime in an operator station client. If an operator wishes to optimize a setting of a controller, he or she can test this in parallel with operation on a virtual plant section before playing this into the real plant section.

[0033] FIG. 2 shows by way of example a functional diagram of a coexistent digital twin for a staged commissioning. In this exemplary embodiment, virtual counterparts (VOS1 and VAS1) exist for each of several real components (operator station server OS1 and the automation device AS1) on the server S with the plant simulator SIMIT for virtualizing the field level. The virtual components VAS1, VOS1 and SIMIT are interlinked via the logical connection (shown with a dashed line) and with the client computer. The client can switch flexibly between a digital (partial) twin and the engineering of the real components in the engineering server ES. Access by the client computer to the engineering server is symbolized with a thick black line. During engineering, the project engineer can observe (debug), correct and also reload the automation program executed in the VAS1 on the client, for instance. The plant images can be visualized and tested in VOS1 in parallel. If error corrections are required, then these can also be performed and reloaded at the same time in engineering. If the commissioning is complete, then the automation programs and plant images from the virtual components can, as described previously, be allocated to the real devices and loaded. Both the real plant as well as the digital (partial) twin are configured and monitored by the integrated engineering in accordance with the invention.

[0034] FIG. 3 is flowchart of the method for engineering an automation system A for controlling a process in a technical plant, where the automation system A comprises a plurality of hardware components OS1, OS2, AS1, AS2, . . . for performing display, operating and automation functions, and where the plurality of hardware components OS1, OS2, AS1, AS2, . . . are interconnected via communication systems. The method comprises virtualizing, generating as a coexistent digital twin, instantiating and logically linking, in parallel with engineering of at least one real hardware component, said at least one real hardware component with other virtual or real components, as indicated in step 310.

[0035] Next, generated virtual components VOS1, VOS2, VAS1, VAS2, . . . are distributed in any desired manner onto servers ES, S of the automation system A such the generated virtual components VOS1, VOS2, VAS1, VAS2, . . . are configured, optimized and monitored by at least one client and such that, during engineering, switching between real components and virtual components to perform changes becomes possible, as indicated in step 320.

[0036] 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.