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System and Method for a Human Machine Interface based Automatic Generation of Process Simulation Models

IP.com Disclosure Number: IPCOM000212470D
Publication Date: 2011-Nov-14
Document File: 9 page(s) / 1M

Publishing Venue

The IP.com Prior Art Database

Related People

Mario Hoernicke, ABB AG: INVENTOR [+3]

Abstract

A method and a system are presented for the automatic generation of process simulation models running on existing operator graphics acting as Human Machine Interfaces of control systems in e.g. manufacturing and process industry. The automatic generation bases on the HMI data model itself augmented by hierarchical data models of the technical plant. According to a new idea, the HMI itself acts as interface between the human and the underlying automation system as well as interface between the human and a simulation at the same environment. This replaces the need of separate simulation tools and hence significantly improves usability. The modeling scope concerns the execution of an efficient factory acceptance test (FAT) as well as engineering, verification and training.

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System and Method for a Human Machine Interface based Automatic Generation of Process Simulation Models

 

Abstract

A method and a system are presented for the automatic generation of process simulation models running on existing operator graphics acting as Human Machine Interfaces (HMI hereafter) of control systems in e.g. manufacturing and process industry. The automatic generation bases on the HMI data model itself augmented by hierarchical data models of the technical plant. According to a new idea, the HMI itself acts as interface between the human and the underlying automation system as well as interface between the human and a simulation at the same environment. This replaces the need of separate simulation tools and hence significantly improves usability. The modeling scope concerns the execution of an efficient factory acceptance test (FAT) as well as engineering, verification and training.

Process simulation models can efficiently be used for operator training systems (OTS hereafter) to train operators about how to operate a plant, before the real start-up takes place, as well as to train new operators or to refresh training for experienced operators. Another example for the efficient use of simulation is the design of chemical processes themselves during the FEED (Front End Engineering and Design) phase. If such process simulation tasks are applied, usually cost intensive and high-fidelity process simulation models have to be developed. Therefore, OTS or FEED models are only used if the customer specifically asks for it and if he is willing to pay the modeling effort.

Where applicable, OTS models are being applied for functional tests of the process control systems. Despite the fact that this enables the use of a detailed model during the FAT, a range of additional problems arises. In this context two main aspects have to be named: the development of OTS models requires experts and may take several months so that they are finished late within the engineering process. Second, the use of OTS models requires specialized and separate training simulator systems. Those tools are usually not available for engineers during FAT and DCS-checkout. Because of the mentioned problems, only very low detailed simulation models are used within FAT and DCS-checkout. Most tasks are still performed manually and therefore, the FAT is a time consuming, cost-intensive, error prone and manual process.

According to a new idea a system and method are introduced for the automatic generation of process simulation models based on available data. This approach uses the HMI as modeling data source, augmented by structured engineering data from the detail engineering phase and can therefore be applied instantly during the development of the automation system solution. This, of course, includes the FAT as well as early module-, and integration-tests. Finally, this enables to parallelize the phases of control- and HMI engineering and to combine intermediate results...