Kernel-Space Network Emulation for Industrial Control Simulation
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Solution Overview
Problem
Conventional engineering workflows for designing and testing industrial automation systems require separate tools for mechanical and control engineering, leading to difficulties in maintaining synchronization between mechanical and control designs, and the need for separate virtual simulation models for testing control programming.
Innovation Solution
An integrated CAD system that allows users to label mechanical CAD models with aspect metadata, transforming them into simulation-capable digital twins that can be exported to a simulation platform for testing control logic and monitoring simulated operations, along with a network emulator instantiated as a device driver in the kernel space to emulate control networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate tools are used for mechanical and control engineering workflows, then each domain can be designed independently, but maintaining synchronization between mechanical and control designs becomes difficult
Solution Approach 1:
The patent merges mechanical and control engineering workflows into a single integrated CAD platform. The system combines mechanical design tools with control programming tools, allowing both domains to be developed within one environment. This integration ensures that mechanical and control designs remain synchronized through shared data models and real-time updates, eliminating the information loss that occurs with separate tools.
Solution Approach 2:
The CAD platform is designed as a universal system that performs multiple functions: mechanical design, control programming, simulation, and testing. This multi-functional platform serves both mechanical engineers and control engineers simultaneously, allowing them to work on their respective domains while maintaining automatic synchronization through the unified system architecture.
2Adaptability or versatility
If separate virtual simulation models are used for testing control programming, then control logic can be tested independently, but the complexity of the testing process increases
Solution Approach 1:
The patent combines the virtual simulation model with the control programming environment into a unified testing platform. The simulation capabilities are integrated directly into the CAD system, allowing control logic to be tested within the same environment where it was developed. This eliminates the need for separate simulation tools and reduces the complexity of setting up and managing virtual test environments.
Solution Approach 2:
The system creates a virtual copy of the mechanical system within the CAD platform that can be used for simulation and testing. This virtual model is automatically generated from the mechanical design data, ensuring consistency between the physical and virtual representations. The copied virtual model can be used for independent control logic testing while maintaining synchronization with the actual mechanical design.
3Device complexity
If an integrated CAD system is used to unify mechanical and control domains, then workflow complexity is reduced, but the system must handle significantly more diverse functions
Solution Approach 1:
The integrated CAD system is organized into distinct functional modules: mechanical design module, control programming module, simulation module, and testing module. Each module handles specific tasks independently but communicates through standardized interfaces and shared data structures. This segmentation allows the system to manage diverse functions while maintaining organizational clarity and reducing overall complexity.
Solution Approach 2:
The patent introduces a central data model and communication interface that acts as an intermediary between different functional modules. This intermediary layer manages data exchange between mechanical and control domains, coordinates simulation processes, and synchronizes testing activities. By centralizing the coordination function, the system can handle diverse operations without increasing workflow complexity for users.
Data Source
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AI summary
An industrial simulation system simulates an industrial automation system using a virtual model or digital twin of the automation system and emulated execution of an industrial control program. The simulation system also emulates the control network over which the industrial controller will communicate with field devices of the automation system. In order to emulate the control network without the need for a separate piece of hardware external to the hardware on which the main simulation executes, the simulation system instantiates a network emulator as a device driver or virtual machine in the kernel space of the hardware platform on which the simulation executes. The network emulator monitors data traffic between user space and kernel space, processes a subset of the data traffic relating to the simulation, and returns results of the processing to the main simulation in user space.