Distributed Simulation Synchronization for Industrial Control Systems
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Solution Overview
Problem
Complex industrial control systems require efficient simulation and synchronization of distributed components to predict performance, throughput, and cost, but existing methods struggle with computational bottlenecks and synchronization issues, especially in large-scale systems.
Innovation Solution
A distributed simulation system that generates a model of industrial control systems using a scenario-based approach, coordinates simulation across multiple computing resources, and employs adaptive time management and implicit synchronization to mitigate bottlenecks and ensure synchronized execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distributed simulation is implemented across multiple computing resources, then predictive power and analysis capability are improved, but synchronization difficulties and computational bottlenecks worsen
Solution Approach 1:
The patent divides the industrial control system into multiple independent simulation components that can be distributed across different computing resources. Each component simulates specific devices or control elements separately, allowing parallel processing while maintaining individual autonomy. This segmentation enables the system to scale across multiple computers without requiring centralized coordination of every simulation detail.
Solution Approach 2:
The patent introduces a communication infrastructure that acts as an intermediary between distributed simulation components. This intermediary layer handles data exchange, event coordination, and state synchronization between components running on different computing resources, abstracting away the complexity of direct peer-to-peer synchronization and enabling seamless distributed operation.
2Reliability
If more components are incorporated into the simulation, then predictive power is improved, but computational bottlenecks worsen
Solution Approach 1:
By segmenting the simulation into independent components that can be distributed across multiple computing resources, the patent enables parallel processing of simulation tasks. This allows the system to incorporate more components and devices in the simulation model without proportionally increasing the computational burden on a single processor, as the workload is distributed across multiple computing nodes.
Solution Approach 2:
The patent transitions from single-computer simulation to multi-computer distributed simulation, adding a spatial dimension to the computational architecture. This dimensional change allows the system to handle larger-scale industrial control systems by distributing computational tasks across a network of computers, effectively increasing the system's capacity to simulate complex multi-device environments.
3Adaptability or versatility
If simulation data is shared across multiple directions, then adaptability is improved, but data coordination complexity worsens
Solution Approach 1:
The patent implements a universal communication infrastructure that handles multiple types of data exchanges between simulation components. This multi-functional communication layer supports various data sharing scenarios (device states, control signals, event notifications, parameter updates) through a unified mechanism, eliminating the need for separate coordination systems for each data type and direction.
Solution Approach 2:
The communication infrastructure acts as an intermediary that manages data sharing between distributed simulation components. It provides standardized interfaces and protocols for data exchange, automatically handling the coordination of multi-directional data flow between components, thereby reducing the complexity that would otherwise arise from direct peer-to-peer data coordination.
4Productivity
If front-loading design changes are implemented through simulation, then manufacturing efficiency is improved, but simulation computational requirements worsen
Solution Approach 1:
The patent enables simulation of complete industrial control systems with multiple devices and control elements distributed across computing resources. This segmented architecture allows comprehensive front-loading of design analysis without overwhelming single-computer computational resources, as the simulation workload is distributed and processed in parallel across multiple computing nodes.
Solution Approach 2:
The patent facilitates front-loading by enabling comprehensive simulation of manufacturing processes during the design phase. Engineers can evaluate design alternatives, optimize control logic, and identify potential issues before actual manufacturing implementation, performing these analytical actions preliminarily in the virtual environment. The distributed architecture makes this comprehensive preliminary analysis computationally feasible.
Data Source
AI summary
System(s) and method(s) facilitate a distributed simulation of an industrial control system. A model of the industrial control system is generated and computing resources are scheduled for simulating portions of a simulation according to the model. Computing resources are scheduled to mitigate computational bottlenecks in the simulation and synchronize portions of the simulation deployed in disparate computing resources. Sub-processes of a control process can be simulated in dedicated computing resources as a part of a distributed simulation of the control process. Execution time of one or more portions of a distributed simulation can be increased or slowed down to synchronize said portions.