Industrial Controller Interface for Machine Simulation Data Exchange
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Solution Overview
Problem
Current simulation technologies for industrial equipment lack effective integration with industrial controller systems, limiting the ability to simulate and control industrial machines accurately in automation environments.
Innovation Solution
An API is used to establish a communication link between a simulation model and an industrial controller system, enabling data exchange and bidirectional connectivity, allowing for the simulation of industrial machines with virtual representations and control signals, thereby enhancing the simulation's utility and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation technologies are used for industrial equipment, then virtual representation and operation emulation are achieved, but effective integration with industrial controller systems is lacking
Solution Approach 1:
The patent introduces an API (Application Programming Interface) as an intermediary component that bridges the simulation application and the industrial controller system. This API enables standardized data exchange and communication protocols, allowing the simulation model to interact effectively with the physical controller without requiring deep customization of either system. The API acts as a mediator that translates between different data formats and communication protocols.
Solution Approach 2:
The patent implements a universal interface architecture that can work with multiple types of industrial controllers and simulation applications through standardized protocols. The system uses common data exchange formats and communication standards that make it adaptable to different controller brands and simulation tools, enhancing versatility while maintaining reliable integration.
2Ease of manufacture
If industrial controller systems are integrated with simulation models, then control logic validation is enabled, but system complexity increases
Solution Approach 1:
The patent divides the integration architecture into distinct functional segments: the simulation application layer, the API interface layer, and the industrial controller layer. This segmentation allows each component to be developed, tested, and maintained independently. The control logic validation capability is isolated to specific functions within the API layer, reducing overall system complexity while enabling thorough validation.
Solution Approach 2:
The API serves as an intermediary that simplifies the integration complexity by providing pre-built communication protocols and data translation capabilities. Rather than creating custom integration code for each controller-simulation pair, the API handles the complexity of protocol translation, data formatting, and error handling, making control logic validation easier to implement.
3Adaptability or versatility
If data exchange is implemented between controller and simulation, then bidirectional connectivity is achieved, but communication overhead increases
Solution Approach 1:
The patent implements parameter optimization in the data exchange protocol, using appropriate data types, precision levels, and update frequencies that match the specific requirements of the simulation and controller. By carefully selecting communication parameters such as data packet size, update rate, and precision requirements, the system achieves bidirectional connectivity with minimized communication overhead.
Solution Approach 2:
The system exchanges only the necessary data required for accurate simulation and control validation, rather than transmitting all possible data. The API filters and prioritizes data exchange based on simulation needs and controller capabilities, reducing communication overhead while maintaining essential bidirectional connectivity for control logic validation.
Data Source
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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.