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EP-4741982-A1 - METHOD FOR CONTROLLING A DOSING PROCESS AND SYSTEM FOR CONTROLLING A DOSING PROCESS

EP4741982A1EP 4741982 A1EP4741982 A1EP 4741982A1EP-4741982-A1

Abstract

A method for controlling a dosing process using a physical dosing system (22) and a system (10) for controlling a dosing process are provided. At least one dosing request is received by an analysis module (12). The analysis module (12) is coupled to the physical dosing system (22), which executes the dosing request. Different dosing processes are simulated by the analysis module (12) based on different applied dosing parameters. The analysis module (12) determines the dosing parameters for which the at least one dosing request is fulfilled. An output signal is sent from the analysis module (12) to the physical dosing system (22) based on the determined dosing parameters. An error message is issued if the analysis module cannot determine any dosing parameters for which the at least one dosing request is fulfilled.

Inventors

  • März, Anne

Assignees

  • Bürkert Werke GmbH & Co. KG

Dates

Publication Date
20260513
Application Date
20241112

Claims (15)

  1. Method for controlling a dosing process using a physical dosing system (22), wherein the method comprises at least the following steps: - Receiving at least one dosing request by an analysis module (12) coupled to the physical dosing system (22) that implements the dosing request, - Simulating different dosing processes based on different applied dosing parameters using the analysis module (12), - Output of determined dosing parameters via an output signal from the analysis module (12) to the physical dosing system (22), provided that at least one dosing request based on the dosing parameters determined by the analysis module (12) is fulfilled, and - Outputting an error message if the analysis module (12) cannot determine any dosing parameters for which at least one dosing requirement is met.
  2. Method according to claim 1, characterized in that the analysis module (12) compares the determined dosing parameters with dosing parameters applicable to the physical dosing system (22).
  3. Method according to claim 1 or 2, characterized in that the analysis module (12) is independent of the physical dosing system (22), so that the analysis module (12) can simulate dosing processes for different physical dosing systems (22).
  4. Method according to one of the preceding claims, characterized in that the analysis module (12) controls and/or parameterizes the physical dosing system (22) based on the determined dosing parameters, such that the physical dosing system (22) fulfills at least one dosing requirement.
  5. Method according to one of the preceding claims, characterized in that the analysis module (12) simulates the dosing process in real time.
  6. Method according to one of the preceding claims, characterized in that the dosing request is specified by a user input or by a device.
  7. Method according to one of the preceding claims, characterized in that the physical dosing system (22) comprises at least one process sensor (28) which is configured to detect a process variable of the medium to be dosed during the dosing process and to transmit it to the analysis module (12), and wherein the analysis module (12) takes the detected process variable into account when simulating the different dosing processes.
  8. Method according to one of the preceding claims, characterized in that the physical dosing system (22) comprises at least one environmental sensor (30) which is configured to detect at least one environmental parameter of the physical dosing system (22) and transmit it to the analysis module (12), and wherein the analysis module (12) takes the detected environmental parameter into account when simulating the different dosing processes.
  9. Method according to one of the preceding claims, characterized in that when simulating the different dosing processes, a virtual dosing system (32) is taken into account, which is formed in a virtual process environment (34) corresponding to a real process environment (24) in which the physical dosing system (22) is arranged, such that the virtual dosing system (32) behaves in the virtual process environment (34) corresponding to the physical dosing system (22) in the real process environment (24).
  10. Method according to claim 9, characterized in that a virtual process variable of the medium to be dosed is simulated via the virtual dosing system (32), wherein the virtual process variable corresponds to a real process variable that is measured by a process sensor (28) of the physical dosing system (22) is detected, wherein an offset between the virtual process variable and the real process variable is determined, and wherein the output signal is adjusted based on the determined offset, or wherein the virtual dosing system (32) in the virtual process environment (34) is adjusted based on the offset.
  11. Method according to one of the preceding claims, characterized in that the at least one dosing request comprises a dosing quantity, a dosing frequency and/or a medium to be dosed.
  12. System (10) for controlling a dosing process, wherein the system (10) comprises at least one physical dosing system (22) and an analysis module (12) coupled to the physical dosing system (22), wherein the analysis module (12) is configured to simulate different dosing processes of the physical dosing system (22) based on at least one dosing request, and wherein the analysis module (12) is configured to output determined dosing parameters to the physical dosing system (22) by means of an output signal, provided that the at least one dosing request is fulfilled based on the dosing parameters determined by the analysis module (12), and to output an error message if no dosing parameters could be determined for which the at least one dosing request is fulfilled.
  13. System (10) according to claim 12, characterized in that the analysis module (12) is configured to simulate the dosing process in real time.
  14. System (10) according to claim 12 or 13, characterized in that the system (10) is configured to simulate a virtual dosing system (32) which is configured in a virtual process environment (34) which is configured corresponding to a real process environment (24) in which the physical dosing system (22) is arranged, such that the virtual dosing system (32) in the virtual process environment (34) behaves correspondingly to the physical dosing system (22) in the real process environment (24).
  15. System (10) according to one of claims 12 to 14, characterized in that the physical dosing system (22) comprises at least one process sensor (28) which is configured to measure a process variable of the to detect the dosing medium during the dosing process and transmit it to the analysis module (12), wherein the analysis module (12) is configured to take the detected process variable into account when simulating the different dosing processes, and/or that the physical dosing system (22) includes at least one environmental sensor (30) which is configured to detect at least one environmental parameter of the physical dosing system (22) and transmit it to the analysis module (12), wherein the analysis module (12) is configured to take the detected environmental parameter into account when simulating the different dosing processes.

Description

The invention relates to a method for controlling a dosing process by means of a physical dosing system and a system for controlling a dosing process. In many industrial sectors, the precise dosing of liquids, gases, or other media is crucial for numerous applications. Plant operators therefore require customized solutions to precisely dose various media in specific quantities and frequencies, for example, to produce desired mixtures. Existing dosing systems are often inefficient because they lack monitoring and control mechanisms. Even when present, a control device requires precise system information to control and/or parameterize a physical unit, such as a sensor within the dosing system, to achieve the desired dosage. While test doses or adjustment processes can be used to calibrate the sensor, these result in downtime for the dosing systems, reducing productivity. Furthermore, dosing systems are subject to varying internal and external influences. For example, the dosing process is affected by fluctuating environmental conditions. Additionally, the dosing medium itself can also influence the process. As a result, a physical unit, such as a sensor, can exhibit divergent behavior depending on the variables mentioned only as examples, leading to inconsistencies in the dosing processes and resulting in increased rejects. The object of the invention is to increase the efficiency and precision of a dosing process and a corresponding dosing system. The problem is solved according to the invention by a method for controlling a dosing process using a physical dosing system. At least one dosing request is received by an analysis module. The analysis module is coupled to the physical dosing system, which executes the dosing request. Different dosing processes are simulated by the analysis module based on different applied dosing parameters. Determined dosing parameters are output from the analysis module to the physical dosing system via an output signal, provided that the at least one dosing request is fulfilled based on the dosing parameters determined by the analysis module. An error message is output if the analysis module cannot determine any dosing parameters for which the at least one dosing request is fulfilled. The method is based on the understanding that simulating dosing parameters can be used to evaluate whether dosing parameters can be determined for the dosing system that meet the dosing requirements. This eliminates the need to evaluate whether the dosing requirements can be met based on the physical dosing system. Therefore, manual test dosing and/or adjustment processes are no longer necessary. Additionally, downtime of the physical dosing system can be avoided, thus increasing operational efficiency. Since the evaluation of whether the dosing requirement is met by the corresponding dosing parameters is performed within a simulation, a large number of different dosing parameters can be considered. In other words, the evaluation can be carried out with regard to a larger parameter space than is possible in the same time and/or with comparable effort through physically performed test doses. Therefore, the method is more efficient than known methods. In particular, this results in less effort for the user, as the user does not have to physically perform numerous test doses. Additionally, the information content for the user is also higher compared to known methods. This is improved because the user gains immediate certainty from the error information if no dosing parameters can be determined that would allow the dosing request to be fulfilled. The user receives this information without having to perform test doses. Optionally, the analysis module compares the determined dosing parameters with dosing parameters applicable to the physical dosing system. This ensures that the analysis module considers the entire application range of the physical dosing system. Since dosing parameters that cannot be implemented by the physical dosing system do not need to be included in the simulation, the analysis effort can be reduced and the simulation can be performed efficiently overall. Preferably, the analysis module is independent of the physical dosing system, allowing it to simulate dosing processes for different physical dosing systems. For example, the analysis module can be implemented as a software application. Since different dosing systems for different applications often differ significantly, such as those used in the food industry versus the chemical industry, this expands the application range of the method. According to one aspect, the physical dosing system can be controlled and/or parameterized by the analysis module based on the determined dosing parameters in such a way that the physical dosing system fulfills at least one dosing requirement. For example, the physical dosing system can be controlled and/or parameterized within the framework of the output signal provided by the analysis module.