Manufacturing automation system components compatibility and performance testing with integrated virtual and real environment

Abstract

A system and method for providing an integrated virtual and real emulation environment for a manufacturing process to provide component compatibility testing and system performance prediction. In one embodiment, a real manufacturing system includes one or more real components that are controlled by a programmable logic controller. The real component can be replaced with a virtual component to determine whether it is compatible in the process, where the programmable controller sends signals to and receive signals from the virtual component as if it were the real component. For system performance prediction, a virtual manufacturing process is provided that includes virtual components where the virtual process is controlled by a programmable logic control as if it were a real process to determine the performance of a real system using the virtual process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of the filing date of Provisional Application No. 60 / 976,101 titled Methods of Integrating Real and Virtual World Using Coupled Sensor / Actuator, filed Sep. 28, 2007.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]This invention relates generally to a system and method for emulating a manufacturing automation system and, more particularly, to a system and method for emulating a manufacturing automation system using coupled virtual and physical sensors / actuators to provide component compatibility testing and system performance prediction.[0004]2. Discussion of the Related Art[0005]Various approaches are known in the art for testing and debugging manufacturing automation systems and processes. One approach is referred to as a traditional field test where testing of new physical equipment using existing systems can be achieved by either setting up a duplicate testing purpose only system or u...

AI Technical Summary

Benefits of technology

[0011]In accordance with the teachings of the present invention, a system and method are disclosed for providing an integrated virtual and real emulation environment for a manufacturing process to provide component compatibility testing and system performance prediction. In one embodiment, a real manufacturing system includes one or more real components that are controlled by a programmable logic controller. The real component can be replaced with a virtual compon...

Problems solved by technology

While there is excessive cost associated with creating and maintaining a duplicate testing purpose only system, testing using the plant requires interrupting current production.

Also, the field testing is not feasible when the new physical equipment is unobtainable.

Furthermore, creating a 100% complete and accurate virtual environment is not likely to be realized in the near future.

Current virtual emulation approaches require extensive model development that requires costly engineering time and software investment.

Emulation is increasingly used for virtual testing of complex automation systems, but it cannot guarantee the complete correctness of a given automation system because of the inaccuracies in a particular model.

The development of simulation models requires additional time and engineering expertise.

Highly accurate model development is time consuming, expensive and sometimes not possible.

Field testing and debugging requires the availability of new equipment and access to deployed automation systems that may result in costly regular production shutdown.

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