Controller Emulator Synchronization for Field Network Simulation
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Solution Overview
Problem
Current simulation technologies for factory automation systems do not accurately reproduce the communication mode of industrial networks on computers, limiting the ability to simulate the behavior of factory automation systems effectively.
Innovation Solution
An information processing device with emulators for controllers and actuators that simulate the behavior of controllers and driving devices, allowing for data exchange and synchronization of command values based on a communication period, enabling accurate reproduction of the communication mode of industrial networks on a computer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current simulation technologies are used, then simulation capability is provided, but the communication mode of industrial networks is not accurately reproduced
Solution Approach 1:
The patent creates virtual copies of industrial network components (controllers and driving devices) through emulator programs. These emulators replicate the communication behavior and data exchange patterns of actual industrial network devices, enabling accurate reproduction of communication modes without requiring physical hardware. The master controller emulator and slave controller emulators copy the exact communication protocols and data structures used in real industrial networks.
2Adaptability or versatility
If multiple controller emulators with different control programs are used, then versatility is improved, but data exchange synchronization becomes complex
Solution Approach 1:
The patent introduces a master controller emulator as an intermediary that mediates data exchange between multiple slave controller emulators. The master controller receives data from slave controllers, processes it according to the communication period, and distributes updated data back to the slaves. This intermediary structure simplifies synchronization by centralizing the coordination logic, allowing different control programs to exchange data systematically without direct peer-to-peer complexity.
Solution Approach 2:
The system implements periodic data exchange between controllers based on a defined communication period. The master controller emulator updates slave controller emulators at regular intervals, creating a rhythmic synchronization pattern. This periodic action ensures that all controllers remain synchronized while accommodating different control program types, as the timing structure provides a common reference frame for data exchange.
Data Source
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AI summary
A technology for reproducing a communication mode of a field network on a computer is desired. An information processing device (100) includes first and second actuator emulators (155, 165), first and second controller emulators (151, 161), and a storage device that stores first and second data (130A, 130B). The first controller emulator (151) calculates first command value for the first actuator emulator (155) using the first data (130A) as an input at each first control period and updates the second data (130B) with data that is a collection target. The second controller emulator (161) calculates second command value for the second actuator emulator (165) using the second data (130B) as an input at each second control period and updates the first data (130A) with the data that is the collection target.