Enhanced simulation models for automation

• US 7,809,534 B2
• Filed: 09/28/2007
• Issued: 10/05/2010
• Est. Priority Date: 09/28/2007
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Drake, Glenn Richardson, Takus, A David, Crooks, Cory R, O'Neill Kolt, Genevieve, Palmieri, Frank Anthony Jr., Glavach, Mark Anson, Sturrock, David Thayer
• Primary Examiner(s): PHAN, THAI Q
• Application Number:
  US11/864,693
• Publication Number:
  US 20090089032A1
• Time in Patent Office: 1,103 Days
• Field of Search: 703/22, 703/2, 703/6, 707/8, 717/113, 700/37
• US Class Current: 703/2
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G06F 2111/08 Probabilistic or stochastic CAD
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30

Abstract

A simulation tool for an industrial automation system is provided. The tool includes a simulation component that simulates one or more components of an industrial control system. At least one directed model provides one or more suggested parameters or profiles to the simulation component, where the suggested parameters or profiles are derived from data relating to an industry or controls application.

Claims

1. A simulation tool for an industrial automation system, comprising:

a simulation component that creates a simulation model for at least one component of the industrial automation system according to a plurality of parameters; and

at least one directed model that derives at least one of the plurality of parameters from an industry profile, wherein the industry profile includes at least one of performance data for the industry or performance data for industrial components that operate in the industry.

2. The simulation tool of claim 1, the simulation component creates the simulation model as a re-usable model for the at least one component of the industrial automation system.

3. The simulation tool of claim 1, the simulation component creates the simulation model as a run-time module for the at least one component of the industrial automation system.

4. The simulation tool of claim 1, further comprises an optimization component that runs the simulation model at least twice and, for each run, evaluates a unique combination of the plurality of parameters to determine the plurality of parameters that at least one of maximizes or minimizes an objective function.

5. The simulation tool of claim 1, the directed model further comprises at least one of a device model, an industry model, or a manufacturing model.

6. The simulation tool of claim 1, further comprising an implementation component that downloads an executable runtime code for the simulation model to a controller.

7. The simulation tool of claim 1, the at least one directed model mines the historical data from at least one database.

8. The simulation tool of claim 1, further comprising an input component that accepts a set of specifications from a user, the specifications include design preferences, performance goals, or objectives.

9. The simulation tool of claim 8, further comprising an identifier component that determines components or methodologies suitable to achieve specifications set forth by a user.

10. The simulation tool of claim 8, further comprising a logic component that determines whether the specifications are within manufacturing capabilities.

11. The method of claim 1, further comprising executing the simulation model into at least one runtime code module.

12. The method of claim 11, the runtime code modules are associated with ladder logic, Sequential Function Logic, input/output module codes, communication codes, or remote Internet interface code.

13. A method of generating simulation code for an industrial automation system, comprising:

generating a simulation model for at least one component of the industrial automation system according to a plurality of parameters;

deriving at least one of the plurality of parameters from past experiences databases for an industry; and

storing the simulation model.

14. The method of claim 13, further comprising:

receiving a set of specifications for a simulation of a process in the industrial automation system;

selecting the at least one component of the industrial automation system for the simulation of the process in the industrial automation system ; and

associating the simulation model with the simulation of the process in the industrial automation system.

15. The method of claim 13, further comprising:

running the simulation model in a simulation;

identifying that the simulation model failed the simulation;

changing at least one of the plurality of parameters and creating an alternative simulation model; and

re-executing the simulation with the alternative simulation model.

16. The method of claim 15, further comprising monitoring the simulation and determining the at least one of the plurality of parameters to change.

17. The method of claim 15, further comprising learning the alternative simulation modules via at least one classifier process.

18. The method of claim 13, further comprising

receiving at least one specification, comprising a plurality of fields;

associating the plurality of parameters with the plurality of fields.

19. The method of claim 13, generating the simulation model further comprising generating the simulation model for at least one of a controller, an input/output module, a communication module, or an intelligent module.

20. A method for generating executable control code, comprising:

defining at least one specification of a control system;

generating at least one directed model from the specifications, the at least one directed model comprising at least one of a device model, an industry model, or a manufacturing model;

generating a simulation model based at least in part upon the at least one directed model and the at least one specification; and

executing the simulation model to simulate a process in the control system.