Generating digital twin systems for multiphysics systems

Patent metadata

Field	Value
Publication number	US-12422794-B2
Application number	US-202217933314-A
Country	US
Kind code	B2
Filing date	Sep 19, 2022
Priority date	Nov 8, 2021
Publication date	Sep 23, 2025
Grant date	Sep 23, 2025

Abstract

A method includes receiving one or more process inputs and one or more process outputs associated with one or more operations of one or more components of an industrial automation system. The method also includes determining a model representative of the one or more components based on the one or more process inputs and the one or more process outputs; identifying a boundary response time threshold associated with an unmeasured operating parameter of the one or more components based on the one or more process outputs; determining one or more inputs to modify the one or more operations of the one or more components based on the boundary response time threshold; and receiving one or more measured outputs of the one or more components after providing the one or more inputs to the model, the one or more measured outputs are acquired before the boundary response time threshold.

First claim

The invention claimed is:

1. A method comprising:
receiving, via one or more processors, one or more process inputs and one or more process outputs associated with one or more operations of one or more components of an industrial automation system;
determining, via the one or more processors, a model representative of the one or more components based on the one or more process inputs and the one or more process outputs;
identifying, via the one or more processors, a boundary response time threshold associated with an unmeasured operating parameter of the one or more components based on the one or more process outputs;
determining, via the one or more processors, one or more inputs to modify the one or more operations of the one or more components based on the boundary response time threshold;
providing, via the one or more processors, the one or more inputs to the model;
receiving, via the one or more processors, one or more measured outputs of the one or more components after providing the one or more inputs to the model, wherein the one or more measured outputs are acquired a time period below the boundary response time threshold;
receiving, via the one or more processors, one or more predicted outputs from the model based on the one or more inputs;
determining, via the one or more processors, the unmeasured operating parameter based on a state estimator configured to employ the one or more predicted outputs and the one or more measured outputs to determine the unmeasured operating parameter; and
adjusting, via the one or more processors, an electrical power provided to one or more motors associated with the one or more components based on the unmeasured operating parameter.

2. The method of claim 1 , comprising identifying the boundary response time threshold by:
determining a maximum response time threshold of the one or more components;
performing a response to test to confirm the maximum response time threshold; and
identifying the boundary response time threshold as a value less than or equal to the maximum response time threshold based on confirming the maximum response time threshold.

3. The method of claim 1 , wherein the state estimator comprises an observer gain between the one or more predicted outputs and the one or more measured outputs.

4. The method of claim 1 , comprising:
determining, via the one or more processors, a class associated with operation of the one or more components based on the unmeasured operating parameter, wherein the class comprises at least one of a linear time invariant, a linear time variant, or a nonlinear relationship between the operating parameter and the operation of the one or more components; and
modifying, via the one or more processors, the operation based on the class.

5. The method of claim 1 , wherein determining the model comprises:
receiving design information indicating an arrangement of one or more industrial automation components;
determining a motion profile of the one or more industrial automation components based on the design information; and
determining the model based on the motion profile of the one or more industrial automation components.

6. The method of claim 1 , wherein modifying the one or more operations of the one or more components based on the unmeasured operating parameter comprises:
generating a digital twin corresponding to the one or more operations based on the unmeasured operating parameter and the model; and
adjusting the one or more operations in accordance with the digital twin.

7. The method of claim 1 , wherein the one or more process inputs comprise measured sensor data, and wherein the unmeasured operating parameter is distinct from the one or more process inputs.

8. A non-transitory computer-readable medium comprising computer-executable instructions that, when executed, are configured to cause a processor to perform operations comprising:
receiving one or more process inputs and one or more process outputs associated with one or more operations of one or more components of an industrial automation system;
determining a model representative of the one or more components based on the one or more process inputs and the one or more process outputs;
identifying a boundary response time threshold associated with an unmeasured operating parameter of the one or more components based on the one or more process outputs;
determining one or more inputs to modify the one or more operations of the one or more components based on the boundary response time threshold;
providing the one or more inputs to the model;
receiving one or more measured outputs of the one or more components after providing the one or more inputs to the model, wherein the one or more measured outputs are acquired at a time period below the boundary response time threshold;
receiving one or more predicted outputs from the model based on the one or more inputs;
determining the unmeasured operating parameter based on a state estimator configured to employ the one or more predicted outputs and the one or more measured outputs to determine the unmeasured operating parameter; and
adjusting an electrical power provided to one or more motors associated with the one or more components based on the unmeasured operating parameter.

9. The non-transitory computer-readable medium of claim 8 , wherein the instructions that, when executed, are configured to cause the processor to determine the model comprises:
receiving design information indicating an arrangement of one or more industrial automation components;
determining a motion profile of the one or more industrial automation components based on the design information; and
determining the model based on the motion profile of the one or more industrial automation components.

10. The non-transitory computer-readable medium of claim 9 , wherein the design information comprises a computer-aided design file.

11. The non-transitory computer-readable medium of claim 8 , wherein the unmeasured operating parameter comprises a position of the one or more components.

12. The non-transitory computer-readable medium of claim 8 , wherein the unmeasured operating parameter comprises an applied torque of the one or more components.

13. The non-transitory computer-readable medium of claim 8 , wherein the state estimator comprises an observer gain between the one or more predicted outputs and the one or more measured outputs.

14. The non-transitory computer-readable medium of claim 8 , wherein the unmeasured operating parameter comprises one or more of a linear velocity of the one or more components, a linear acceleration of the one or more components, a rotational velocity of the one or more components, or a rotational acceleration of the one or more components.

15. A non-transitory computer-readable medium comprising computer-executable instructions that, when executed, are configured to cause a processor to perform operations comprising:
receiving one or more process inputs and one or more process outputs associated with one or more operations of one or more components of an industrial automation system;
determining a model representative of the one or more components based on the one or more process inputs and the one or more process outputs;
identifying a boundary response time threshold associated with an unmeasured operating parameter of the one or more components based on the one or more process outputs;
receiving an operating parameter from a sensor monitoring the one or more components that is controlled based on the model;
determining that the operating parameter is outside of an operating para

Assignees

• Rockwell Automation Tech Inc

Inventors

• Cook Michael D

Classifications

• G05B13/048

  using a predictor · CPC title

• G05B13/042 Primary

  in which a parameter or coefficient is automatically adjusted to optimise the performance · CPC title

• G05B17/02 Primary

  electric · CPC title