Industrial Network Emulation for Digital Twin Virtual Commissioning
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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 simulation models for virtual commissioning.
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 and testing platform for virtual commissioning, and a network emulation component to accurately emulate the device network for simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate tools are used for mechanical and control engineering, then each tool can be specialized for its specific function, but maintaining synchronization between mechanical and control designs becomes difficult
Solution Approach 1:
The patent combines mechanical and control engineering tools into a single integrated CAD system. The system allows users to create and annotate mechanical CAD models with control-related aspect metadata, and automatically generates corresponding simulation models. This merging eliminates the need for separate tools and maintains synchronization between mechanical and control designs through automated model generation and linking.
2Ease of manufacture
If separate simulation models are created for virtual commissioning, then each simulation can be optimized for its specific purpose, but the complexity of creating and maintaining multiple models increases
Solution Approach 1:
The patent creates a universal simulation model that serves multiple purposes. The system generates a simulation model from the annotated mechanical CAD model that can be used for both mechanical verification and control commissioning. This single multi-functional model replaces the need for separate optimized simulation models, reducing complexity while maintaining the ability to perform various simulation tasks.
Solution Approach 2:
The system performs preliminary actions by automatically generating the simulation model during the CAD design phase, before virtual commissioning is needed. The aspect metadata is attached to the mechanical model in advance, and the simulation model is pre-generated with all necessary control system representations. This preliminary preparation eliminates the need to create separate simulation models later, reducing overall complexity.
3Loss of information
If mechanical CAD models are transformed into simulation-capable digital twins, then synchronized mechanical and control design development is enabled, but the complexity of the CAD system increases
Solution Approach 1:
The patent segments the CAD system functionality into distinct modules: mechanical model creation, aspect metadata annotation, and automatic simulation model generation. Each module handles a specific aspect of the design process, allowing the system to maintain synchronization between mechanical and control designs without becoming an unmanageably complex monolithic system. The segmentation enables clear separation of concerns while achieving integrated functionality.
Data Source
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AI summary
An industrial simulation system (302) 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 includes a network emulation component (314) that emulates the device network over which the industrial controller will communicate with field devices of the automation system. The network emulation component can configure the device network emulation based on controller configuration data obtained by interrogating the hardware controller (1704) executing the control code being tested, as well as I/O point information obtained from the virtual model.