Controller-Simulation API Interface for Virtual Machine Validation
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Solution Overview
Problem
Current industrial automation systems lack an effective method to integrate simulations with real or emulated controllers, limiting the ability to accurately demonstrate and test the functionality of industrial machines during the design and prototyping phases.
Innovation Solution
The integration of an API to establish a communication link between a simulation model and an industrial controller system, enabling bidirectional data exchange and control signal transmission, which allows for the simulation of industrial machines and their components, including three-dimensional visualizations and control of simulated devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If simulation models are used to emulate virtualized operation of industrial equipment, then the ability to design and prototype is improved, but the integration with real controllers is insufficient
Solution Approach 1:
An API layer is introduced as an intermediary between the simulation model and the industrial controller system. This API establishes a communication link that enables data exchange and control signal transmission, allowing the simulation model to interact with the real controller while maintaining separate operational domains. The API acts as a mediator that translates and facilitates communication between the virtual simulation environment and the physical control system.
2Reliability
If industrial controllers are integrated with simulation models, then control logic validation is improved, but system complexity increases
Solution Approach 1:
The API is designed with universal functionality to handle multiple tasks: data exchange, control signal transmission, and validation operations. This multi-functional approach consolidates what would otherwise require separate integration components, reducing overall system complexity while enabling comprehensive controller-simulation integration and control logic validation.
3Loss of time
If data exchange between controllers and simulation models is enabled, then early validation is improved, but communication infrastructure requirements increase
Solution Approach 1:
The physical mechanical connection between controllers and simulation models is replaced with a software-based API communication interface. This substitution eliminates the need for complex physical communication infrastructure while enabling rapid data exchange and early validation of control logic in the virtual environment before physical deployment.
Data Source
AI summary
Systems, methods, and software to facilitate simulating machines used in industrial automation are disclosed herein. In at least one implementation, an API is utilized to establish at least a communication link between a simulation model created in a simulation application and an industrial controller system outside of the simulation model, wherein the simulation model comprises definitions for a virtual representation of at least a portion of a machine used in an industrial automation environment. Data is then exchanged between the industrial controller system and the simulation model over the communication link.