Industrial Controller Digital Twins With Automatic Secure Setup
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Solution Overview
Problem
Current methods for creating digital twins for industrial systems, such as programmable logic controllers (PLCs) and CNC machines, require significant effort and expertise, as they need custom programming and deep knowledge of both the device and software development, with no established automated process for setup and integration.
Innovation Solution
A method involving assigning a unique identifier to a physical component, creating a digital twin on a distributed network, establishing secure communication, and synchronizing data between the physical and digital twins, allowing for automated setup and use before the physical component is installed, with features like version history and secure communication using trust certificates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom programming and manual setup are used to create digital twins, then the digital twin can be created with deep knowledge of the device, but the effort and time required increase significantly
Solution Approach 1:
The patent uses automatic code generation to create digital twins by copying and adapting existing device descriptions and configurations. Instead of manual programming, the system automatically generates the digital twin model from device data, significantly reducing setup time while maintaining accuracy through systematic copying of device characteristics
Solution Approach 2:
The patent implements device description templates and configuration schemas that are prepared in advance. These preliminary structures enable automatic code generation to quickly create accurate digital twins without requiring manual setup during deployment, thus reducing time loss while ensuring reliability
2Adaptability or versatility
If custom programming is required for each digital twin, then the digital twin can be tailored to the specific device, but the complexity of the process increases
Solution Approach 1:
The patent employs universal device description templates and standardized configuration schemas that can be applied across different device types. This universal approach enables automatic code generation to create device-specific digital twins without requiring custom programming for each case, reducing process complexity while maintaining adaptability
Solution Approach 2:
The system uses parameter-based configuration where device-specific characteristics are defined through configurable parameters in templates. By changing parameters rather than rewriting code, the system achieves device-specific customization with reduced complexity, as the same template structure adapts to different devices through parameter variation
3Reliability
If manual integration is used to connect digital twin with physical system, then deep knowledge of software development is required, but the integration process becomes more time-consuming
Solution Approach 1:
The patent implements automatic code generation that self-configures the digital twin integration with the physical device. The system automatically generates connection code, configures data flows, and establishes communication protocols without requiring manual intervention or deep software development knowledge, thus improving ease of operation while maintaining integration accuracy
Solution Approach 2:
The patent introduces an automatic code generation system as an intermediary between the device description and the digital twin implementation. This intermediary automatically translates device specifications into integrated digital twin code, eliminating the need for manual integration work and reducing the knowledge barrier while ensuring accurate integration
Data Source
AI summary
A method for implementing a digital twin for a physical component of an industrial system includes assigning a unique identifier to the physical component, associating the unique identifier with a digital twin representative of the physical component, placing the digital twin of the physical component on a distributed network. The physical component sends the unique identifier to a known resource, which retrieves the network address of the physical twin associated with the unique identifier and provides the network address to the physical component. A secure communication connection is established between the physical component and the corresponding digital twin via the distributed network. The unique identifier may be a quick read (QR) code displayed on the physical component or a bar code displayed on the physical component. Engineering and simulation software for the digital twin may be supplied on the distributed network.