# US 11,079,735 B2 · Control system and method for operating a control system with real control and virtual control > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,079,735 B2 - Document ID: US11079735B2 - Status: Granted - Kind: B2 - Application number: 15/760,965 - Filed: 2016-08-12 - Published: 2018-09-20 - Granted: 2021-08-03 - Earliest claimed: 2015-09-18 - Assignees: Siemens Aktiengesellschaft - Applicants: Siemens Aktiengesellschaft - Inventors: Karl-Josef Amthor; Guido Seeger - Web page: https://patentgrep.com/patent/US11079735B2 ## CPC - G05B 19/4069: Simulating machining process on screen (G05B19/4068 takes precedence) - G05B 17/02: electric - G05B 2219/23445: Real time simulation - G05B 2219/31372: Mes manufacturing execution system - G05B 2219/33301: Simulation during machining - G05B 2219/33324: What to diagnose, whole system, test, simulate - Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract When carrying out an industrial process or during the operation of an industrial system or machine, relevant data is to be detected without additionally loading the control of the industrial process or the system or machine in question. For this purpose, the invention provides a control system (1, 4, 5; 1′, 4′, 5′; 1″, 4″, 5″) with a real control (1; 1′; 1″) for controlling an industrial process, a system or a machine; a virtual control (4; 4′; 4″) for simulating the control of the industrial process, the system, or the machine; synchronization means for synchronizing the real control (1; 1′; 1″) and the virtual control (4; 4′; 4″); and a higher-level processor unit (5; 5′; 5″) for detecting and/or generating operating data and/or state data with respect to the process, the system, or the machine, wherein the operating data and/or state data is based on data originating from the virtual control (4; 4′; 4″). By requesting the data from the virtual control (4; 4′; 4″), the real control (1; 1′; 1″) is not additionally loaded. ## Claims ### Claim 1 A control system, comprising: a real control configured to execute a real control program to control a real industrial process, a real plant or a real machine in real time; a virtual control configured to execute a virtual control program to control a virtual industrial process, a virtual plant or a virtual machine which simulates control of the real industrial process, the real plant or the real machine, wherein the virtual control program is identical to the real control program and performs as a simulation the same control task and in step with the real control and is executed time-synchronously with the real control program while the real industrial process, the real plant or the real machine are operating; and a higher-level processor unit in data communication with the virtual control, the higher-level processor unit receiving diagnostic data with respect to the virtual industrial process, the virtual plant or the virtual machine from the virtual control, wherein most of the diagnostic data are received from the virtual control so as not to additionally burden the real control by reading out the diagnostic data while the real industrial process, the real plant or the real machine are operating and processing the diagnostic data for analysis without losing synchronicity with the real control in the process. ### Claim 2 (depends on 1) The control system of claim 1, wherein the diagnostic data transferred from the virtual control to the higher-level processor unit further includes operating data and/or state data. ### Claim 3 (depends on 1) The control system of claim 1, wherein the real control is configured to transfer time-based data and/or state-based data to the virtual control for time-synchronizing the virtual control with the real control. ### Claim 4 (depends on 1) The control system of claim 1, wherein the real control is configured as a CNC (Computerized Numerical Control) for controlling a machine tool. ### Claim 5 (depends on 1) The control system of claim 1, wherein the real control is connected to a real machine or plant, and the virtual control is connected to a virtual machine or plant. ### Claim 6 A method for operating a real industrial process, a real plant or a real machine, comprising: executing a real control program which controls the real industrial process, the real plant or the real machine by a real control; executing a virtual control program controlling a virtual industrial process, a virtual plant or a virtual machine which simulates the real control of the real industrial process, the real plant or the real machine by a virtual control, wherein the virtual control program is identical to the real control program and performs as a simulation the same control task and in step with the real control and is executed time-synchronously with the real control program while the real industrial process, the real plant or the real machine are operating; and receiving diagnostic data with respect to the virtual industrial process, the virtual plant or the virtual machine by a higher-level processor unit in data communication with the virtual control from the virtual control, wherein most of the diagnostic data are received from the virtual control so as not to additionally burden the real control by reading out the diagnostic data while the real industrial process, the real plant or the real machine are operating, and processing the diagnostic data for analysis without losing synchronicity with the real control in the process. ### Claim 7 (depends on 6) The method of claim 6, wherein the diagnostic data transferred from the virtual control to the higher-level processor unit further includes operating data and/or state data. ### Claim 8 (depends on 6) The method of claim 6, further comprising transferring time-based data and/or state-based data from the real control to the virtual control for time-synchronizing the virtual control with the real control. ### Claim 9 (depends on 7) The method of claim 7, further comprising generating service data in response to a detection of the operating data and/or state data by the higher-level processor unit. ### Claim 10 (depends on 9) The method of claim 9, further comprising transferring the service data automatically to a service provider.