Process simulation utilizing component-specific consumption data

• US 8,670,962 B2
• Filed: 11/20/2012
• Issued: 03/11/2014
• Est. Priority Date: 04/24/2009
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kaufman, Philip John, Walker, Marcia Elaine
• Primary Examiner(s): Frejd, Russell
• Application Number:
  US13/682,194
• Publication Number:
  US 20130080131A1
• Time in Patent Office: 476 Days
• Field of Search: 703/1, 703/6, 703/13, 700/31, 700/291
• US Class Current: 703/6
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30

Abstract

Methods and apparatuses are provided for simulating components and processes using discrete, variable-granularity, component-specific data relating to energy consumption or other sustainability factors. Simulations can be analyzed and optimized to facilitate forecasting of sustainability factors and determine advantageous modifications to the components or processes.

Claims

1. A computer-implemented method, comprising:

accessing component-specific sustainability factor data relating to a physical component of a plurality of physical components of a plant or process;

simulating the physical component based on the component-specific sustainability factor data relating to the physical component;

generating a plurality of alternate consumption scenarios for the physical component based on the simulation of the physical component; and

modifying a control program for the physical component based on at least one of the plurality of alternate consumption scenarios.

2. The computer-implemented method of claim 1, wherein generating the plurality of alternate consumptions scenarios for the physical component comprises varying a granularity of the component-specific sustainability factor data relating to the physical component.

3. The computer-implemented method of claim 2, wherein varying the granularity of the component-specific sustainability factor data relating to the physical component comprises decomposing the simulated physical component into constituent elements, associating a portion of the component-specific sustainability factor data relating to the physical component to each constituent element, and reassembling the associated portions of the component-specific sustainability factor data relating to the physical component.

4. The computer-implemented method of claim 1, comprising determining which of the plurality of alternate consumption scenarios are used to modify the control program based on computations relating to the plurality of alternate consumption scenarios.

5. The computer-implemented method of claim 1, comprising determining which of the plurality of alternate consumption scenarios are used to modify the control program based on a pre-existing setting of the plant or process.

6. The computer-implemented method of claim 1, comprising determining which of the plurality of alternate consumption scenarios are used to modify the control program based on user input.

7. The computer-implemented method of claim 1, wherein modifying the control program for the physical component comprises generating control data for implementing the at least one alternate consumption scenario.

8. The computer-implemented method of claim 1, wherein modifying the control program for the physical component comprises generating transition warnings relating to implementation of the at least one alternate consumption scenario.

9. The computer-implemented method of claim 1, wherein simulating the physical component comprises generating a virtual model of the physical component.

10. The computer-implemented method of claim 9, comprising modifying the virtual model of the physical component based on a change to the simulation of the physical component.

11. The computer-implemented method of claim 10, wherein the change to the simulation of the physical component comprises a modulation in production of the plant or process.

12. The computer-implemented method of claim 1, comprising generating a bill of materials relating to the component-specific sustainability factor data relating to the physical component.

13. An industrial control system, comprising:

a processor configured to execute computer-readable instructions stored on a memory device, the computer-readable instructions including instructions for;

accessing component-specific sustainability factor data relating to a physical component of a plurality of physical components of a plant or process;

simulating the physical component based on the component-specific sustainability factor data relating to the physical component;

generating a plurality of alternate consumption scenarios for the physical component based on the simulation of the physical component; and

modifying a control program for the physical component based on at least one of the plurality of alternate consumption scenarios.

14. The industrial control system of claim 13, wherein generating the plurality of alternate consumptions scenarios for the physical component comprises varying a granularity of the component-specific sustainability factor data relating to the physical component.

15. The industrial control system of claim 14, wherein varying the granularity of the component-specific sustainability factor data relating to the physical component comprises decomposing the simulated physical component into constituent elements, associating a portion of the component-specific sustainability factor data relating to the physical component to each constituent element, and reassembling the associated portions of the component-specific sustainability factor data relating to the physical component.

16. The industrial control system of claim 13, wherein the computer-readable instructions include instructions for determining which of the plurality of alternate consumption scenarios are used to modify the control program based on computations relating to the plurality of alternate consumption scenarios.

17. The industrial control system of claim 13, wherein the computer-readable instructions include instructions for determining which of the plurality of alternate consumption scenarios are used to modify the control program based on a pre-existing setting of the plant or process.

18. The industrial control system of claim 13, wherein the computer-readable instructions include instructions for determining which of the plurality of alternate consumption scenarios are used to modify the control program based on user input.

19. The industrial control system of claim 13, wherein the computer-readable instructions include instructions for generating a bill of materials relating to the component-specific sustainability factor data relating to the physical component.

20. A computer-implemented method, comprising:

accessing component-specific sustainability factor data relating to a physical component of a plurality of physical components of a plant or process;

simulating the physical component based on the component-specific sustainability factor data relating to the physical component, wherein simulating the physical component comprises generating a virtual model of the physical component and modifying the virtual model of the physical component based on modulations in production of the plant or process;

generating a plurality of alternate consumption scenarios for the physical component based on the simulation of the physical component, wherein generating the plurality of alternate consumptions scenarios for the physical component comprises decomposing the simulated physical component into constituent elements, associating a portion of the component-specific sustainability factor data relating to the physical component to each constituent element, and reassembling the associated portions of the component-specific sustainability factor data relating to the physical component; and

modifying a control program for the physical component based on at least one of the plurality of alternate consumption scenarios, wherein modifying the control program for the physical component comprises generating control data for implementing the at least one alternate consumption scenario and generating transition warnings relating to implementation of the at least one alternate consumption scenario.